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TP-2548 Courage Service Manual - K&T Parts House Lawn Mower

1. 331 44 175 16 13 049 6 896 198 65 3 25 TO SPARK Ges 226 22 ied PLUG 108 55 Lifting 8 906 A R 4 313 POINT E Se i TO OIL S FILTER i 10 00 LIFTING 394 POINT 13 00 OIL FILTER 8 30 08 669 Leg REMOVAL 1 184 OIL FILTER TO CARBURETOR SHUTDOWN SOLENOID OPTIONAL ENGINE MOUNTING SURFACE 6 403 CARBURETOR STARTER MOTOR o i LORAIN REGULATOR ect 84 50 RECT I 1 890 OPTIONAL 3 327 oo MOUNTING BOSS 12 917 2X M8 X 1 25 4 821 4 584 2 STUDS 6 3627 T KEYWAY Le 153 7 6 3170 WIDTH vs E 24 i 141 70 2505 25 400 120 00 5 579 2487 25 375 68 00 2 677 4 724 1 000 i 999 A 63 99 80 30 CH Wl 2 519 B161 VALVE COVER VIEW ij a 2 600 ae ACCESSORY MOUNTING TO STARTER LOCATION STUD CORED FOR MG6 20MM LONG T Ge OR 1 4 1 2 1N LONG 3 780 9 840 SELF TAPPIN 7 16 20 UNF 2B IN GROUND LUG 21 82 TO EXHAUST PORT 38 1 859 8 736 851 ENGINE MOUNTING KEYWAY SURF ACE 207 25 el DEPTH Te 159 STARTER VIEW TO OIL FILTER St LEVEL 174 21 120 00 zi i 134 00 6 859 4 724 5 276 Ca SE 213 EXHAUST FLANGE 57 00 MOUNTING SURFACE 2 244 CABLE CLIP CORED FOR M 6 E 139 12 SELF TAPPING SCREW 5 477 a A TAS LO C SS ACCESSORY MOUNTING lao BEEN LOCATION Ke o 0 A a H 45 1B Hm S A e tet
2. 33 5 1 32 tT Z oS 35 310 63 115 00 f s Eh 12 229 4 528 si Q o Nests IN A Gr s65 72 66 27 AN Ur irs V 13 926 2 609 d N ye SYD 118 00 f 4 646 So U a 8 95 LIFTING POINT REI e L 156 12 148 00 k 182 35 235 00 352 6 146 5 827 Aceh ee 7 179 9 252 348 379 POINT 279 45 pe 11 002 MOUNTING FEET 10 000 SESCH FLYWHEEL VIEW AIR CLEANER PTO VIEW COVER REMOVAL Figure 1 4 Typical Engine Dimensions 1 6 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information General Specifications Power 3600 RPM corrected to SAE J1940 e E 11 2 kW 15 HP VOU asec en ps acta E E E E E 11 9 kW 16 HP NEE 12 7 KW 17 HP eeh 13 4 kW 18 HP SNE 14 1 kW 19 HP EE 14 9 kW 20 HP Peak Torque OV ATO 2600 eege 34 3 N m 25 0 ft Ib SV480 2800 RPM cessctorecesancevacaevsncoastseencsanegeencaeseneiseteccesnoreerseasneeees 34 6 N m 25 5 ft Ib DI 2000 RPM eege 37 8 N m 27 9 ft Ib SV540 2800 RPM eebe 39 1 N m 29 0 ft Ib OC 2600 RPM orrien inre EEEE esaeee ci OEE EE 42 3 N m 31 2 ft Ib SVOJO 2800 RPM E 44 2 N m 32 0 ft Ib Bore VAOS OVAS US korei EAEE 84 mm 3 30 in RE S V4 0S aein a aaa 89 mm 3 50 in EE EE 94 mm 3 70 in REO ee 86 mm 3 38 in Displacement E Eege ed 477 cc 29 1 Cu in Sae de Men Lo o eee nnn
3. ceeeeeeeeeeeteeeeeees Air escaping from Carburetor ccccccseseeeeseseeeeeeeeesaees Gauge reading in low green zone Gauge reading in moderate yellow zone Gauge reading in high red zone 3 4 ER Defective rings or worn cylinder walls EEN Defective exhaust valve eessen Defective intake valve RE Piston rings and cylinder in good condition Peer Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement SE Rings and or cylinder have considerable wear Engine should be reconditioned or replaced www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 4 Air Cleaner and Air Intake System Air Cleaner These engines are equipped with a replaceable high density paper air cleaner element Some engines also have an oiled foam precleaner located in the outer air cleaner cover See Figure 4 1 Air Cleaner Base D se Figure 4 1 Air Cleaner Assembly Exploded View Check the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris and loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Intake air is drawn in through the upper opening from the blower housing passes t
4. 3 Compression Ring Top Groove Install the top ring using a piston ring installation tool Make sure the identification mark is up when the ring is installed Connecting Rods Inspection and Service Check the bearing area big end for score marks and excessive wear measure running and side clearances refer to Section 1 Service replacement connecting rods are available in STD crankpin size Oil Pump Assembly and Pressure Relief Valve Inspection and Service The closure plate must be removed to inspect and service the oil pump Refer to the Disassembly and Reassembly Sections 8 and 10 for removal and reinstallation procedures Check the oil pump and gears for cracks damage wear and smooth rotation Replace the pump if any binding is noted or reuse is questionable in any way A pressure relief valve is built into the oil pump to limit maximum pressure It is not serviceable If a problem exists with the pressure relief valve the oil pump assembly should be replaced Governor Gear and Shaft Inspection Inspect the governor gear teeth Look for any evidence of worn chipped or cracked teeth If one or more of these problems is noted replace the governor gear The gear is held on the governor shaft by molded tabs which are damaged when the gear is removed Never reuse the gear once it has been pulled from the shaft Replace the governor shaft only if it is damaged or worn 9 12 Procedur
5. Dirt or water in the fuel system Faulty spark plug Idle fuel adjusting needle improperly set Idle speed adjusting screw improperly set Low compression Stale fuel and or gum in carburetor Engine Overheats 1 St Ge IN Air intake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Engine Knocks 1 2 3 4 Excessive engine load Low crankcase oil level Old improper fuel Internal wear or damage 3 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 3 Troubleshooting Engine Loses Power Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plug Low compression Exhaust restriction oe ee Engine Uses Excessive Amount of Oil Incorrect oil viscosity type Breather clogged or inoperative Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides Crankcase overfilled oror Ee External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled e Check for buildup of dirt and debris on the crankcase cooling fins grass
6. Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition Anormal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve Leakage A poor grind on a valve face or seat will can be reconditioned and reused if the face and allow leakage resulting in a valve burned on one side margin are in good shape If a valve is worn to where only the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 9 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures The white Stem Corros
7. If the resistance is infinity ohms stator is open Replace stator With the engine stopped measure the Ifthe resistance is infinity ohms no resistance from each stator lead to ground continuity the stator is OK not shorted to using an ohmmeter ground If resistance or continuity is measured the stator is shorted to ground Replace stator Perform same test as step 1 above If the voltage is 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as necessary Battery Continuously Charges at High Rate If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator 7 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Electric Starters NOTE If the engine develops sufficient speed to These engines use inertia drive starting motors disengage the inertia drive starter but does not keep running a false start the engine Operation rotation must be allowed to come to a When power is applied to the starter the armature complete stop before attempting to restart the rotates As the armature rotates the drive pinion engine If the starter is engaged while the moves out on the splined drive shaft and into mesh flywheel is rotating the starter pinion and with the flywheel ring gear When the pinion reaches flywheel ring gear may clash
8. Spark Plug Service Spark Plug Every 2 years or 200 hours of operation remove the spark plug Check its condition and reset the gap or replace with a new plug as necessary Spark plug replacement is recommended at 500 hours 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and 0 76 mm debris out of the engine Due to the deep recess 0 030 in around the spark plug blowing out the cavity with Gap compressed air is usually the most effective Electrode method for cleaning The spark plug is most Figure 7 1 Servicing Spark Plug accessible when the blower housing is removed for cleaning 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 30 N m 18 22 ft Ib 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable 5 Reconnect the spark plug lead and reinstall the blower housing if removed previously Torque the blower housing screws to 7 5 N m 65 in Ib 7 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Inspection Inspect the spark plug as soon as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings valves and carburetor Normal and fouled plugs are shown in the following photos epes goes viet Chalky White Deposits Chalky whi
9. 10 16 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly c Torque the nut s to 5 5 N m 48 in Ib Torque the screw to 8 0 N m 70 in Ib into a new hole or 5 5 N m 48 in Ib into a used hole do not over tighten See Figure 10 62 The M6 screw for the upper tab will be installed when the blower housing is mounted Figure 10 59 Air Cleaner Base Upper Mounting Tab Details Figure 10 62 Torquing Air Cleaner Fasteners 10 Attach the breather hose to the valve cover and air cleaner base Install and Adjust Governor Lever 1 Install the governor lever onto the governor shaft with the lever section up Connect the throttle linkage using the black linkage bushing See Figure 10 63 p Figure 10 60 Installing Air Cleaner Base b Models with one screw and one mounting stud only Apply hand pressure to keep the parts from shifting then carefully remove the alignment pin and install DRY the long M6 thread forming screw DO NOT OIL See Figure 10 61 Check to make sure all gaskets are still in proper position NOTE Itis recommended that a new governor lever be installed whenever removal is performed Figure 10 63 Governor Lever Installed on Shaft Figure 10 61 Installing Mounting Screw Models with one stud and one screw 10 17 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10
10. 3 mm diameter drive pin into the upper hole See Figure 10 6 3 Lightly grease the gerotor gears and install into the oil pump with the short drive pin fitted into the slot of the inner gear See Figure 10 7 Figure 10 7 Gerotor Gears Installed in Oil Pump 4 Lightly lubricate the ends of the oil pump outlet seal with oil and install it into the outlet of the oil pump See Figure 10 8 Some models use a solid seal without an oil passage and the crankshaft is cross drilled for lower bearing lubrication Both styles of outlet seals are shown in Figure 10 9 If anew seal was ordered make sure it is the right one for the engine Open Style Pump Outlet Seal Figure 10 8 Installing Oil Pump Outlet Seal Closed Style Figure 10 9 Oil Pump Outlet Seals Install the intake cam shaft down into the crankcase boss Seat the rubber oil pump outlet seal into the machined pocket If an open style outlet seal is used check to make sure the small feed hole is open and aligned with the lower main bearing oil feed hole Use a 3 32 allen wrench or a light with a mirror See Figure 10 10 Push the steel sleeves in the pump housing down until bottomed against the mounting surface Install the two M5 mounting screws Hold the pump outlet against the main bearing area and torque the screws to 4 0 N m 35 in Ib See Figure 10 11 10 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 6
11. Torque the switch to 4 5 5 0 N m 40 45 in Ib 5 Connect the lead to the terminal on the Oil Sentry switch 6 4 Testing the Oil Sentry Switch The Oil Sentry pressure monitor is a normally closed switch It is calibrated to open break contact with increasing pressure and close make contact with decreasing pressure within the range of 2 0 5 0 psi Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch The tester should indicate a change to no continuity switch open as the pressure increases through the range of 2 0 5 0 psi The switch should remain open as the pressure Is increased to 90 psi maximum 3 Gradually decrease the pressure to the switch The tester should indicate a change to continuity switch closed as the pressure decreases through the range of 2 0 5 0 psi approaching 0 psi If the switch does not operate as specified replace the switch Testing Oil Pressure The engine oil pressure can be tested using an oil pressure tester Follow the instructions included with the tester The pressure can be tested by removing the oil filter and installing the tester adapter on the mounting pad or by r
12. arms from the pivot studs 3 Remove the rocker arm pivot studs and push rod guide plates See Figure 8 33 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly t a Figure 8 33 Disassembling Rocker Arm Figure 8 35 Removing Closure Plate Screws Components 2 Agasket is used between the closure plate and 4 Remove the valves crankcase If necessary carefully tap on the bosses for the starter or oil filter with a soft faced a Compress the valve springs using a valve mallet to loosen Do not pry on the gasket spring compressor and remove the keepers surfaces of the crankcase or oil pan as this can See Figure 8 34 cause damage resulting in leaks b Remove the compressor then remove the 3 Remove the closure plate assembly and gasket valve spring caps valve springs and valves See Figure 8 36 4 Ifthe wiring harness needs to be separated from the closure plate pry open the clamps and pull out through the slot Figure 8 34 Removing Valves with Spring Compressor Remove Closure Plate 1 Remove the fourteen hex flange screws Figure 8 36 Closure Plate and Gasket Removed securing the closure plate to the crankcase See from Crankcase Figure 8 35 Note the location and position of any attached clips or clamps 8 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Disassemble Clo
13. bore See Figure 8 45 8 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Figure 8 45 Removing Piston and Connecting Figure 8 47 Removing Piston Rings Rod Remove Crankshaft and Balance Weight Remove Piston from Connecting Rod Assembly 1 Remove the wrist pin retainer and wrist pin 1 Carefully lift the crankshaft and balance weight Se the piston from the connecting rod See assembly out of the crankcase See Figure 8 48 igure 8 46 Figure 8 48 Removing Crankshaft and Balance Figure 8 46 Separating Piston from Connecting Weight Assembly Rod Balance Weight Disassembly Remove Piston Rings a If necessary the balance weight assembly can be 1 Remove the top and center compression rings separated from the crankshaft using a ring expander See Figure 8 47 1 Remove the guide shoe from the guide pin on the 2 Remove the oil control ring rails then remove the flywheel side of the assembly spacer 2 Remove the crank gear from the crankshaft and carefully remove the key from the keyway See Figure 8 49 8 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Remove Governor Cross Shaft 1 Remove the hitch pin and washer located on the outside of the governor cross shaft See Figure 8 52 Figure 8 49 Removing Crank Gear Key 3 Remove the long hex flange screw securing
14. vy Kohler Command 20 10 10 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F 30 weight acceptable above 0 C 32 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 S Figure 1 3 Oil Container Logo Refer to Section 6 Lubrication System for detailed oil check oil change and oil filter change procedures 1 4 Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spil
15. 0 77 mm 0 030 in NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings Install the bottom oil control ring first and the top compression ring last Refer to Figure 9 15 Piston Ring End Gap ee Identification Figure 9 13 Measuring Piston Ring End Gap 4 After installing the new compression top and middle rings on the piston check piston to ring side clearance The maximum recommended side clearance for each ring is 0 04 mm 0 0016 Top Compression in If the side clearance is greater than Ring specified a new piston must be used Refer to H l Figure 9 14 Center Compression Ring Top Compression Ring to Groove Side Clearance csseeseeeeeeees 0 04 mm 0 0016 in Middle Compression Ring to Groove Side Clearance s es 0 04 mm 0 0016 in Expander Oil Control Ring Three Piece Figure 9 15 Piston Ring Installation 9 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of the expander are not overlapped 2 Compression Ring Center Groove Install the center ring using a piston ring installation tool Make sure the identification mark is up when the ring is installed
16. 13 N m 90 110 in Ib 1 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Oil Filter Pad Pipe Plug 1 8 NPN NON QU Co siciee calericcane sai abenecisaesctawecuseencesedtedacncasatsweneetees Oil Pump Mounting Screw TOK EE Pump Gears to Crankcase Gde Clearance Oil Sentry Pressure Switch Torque cccccccssseecceeeeeeeeeesaeeeeeeeeseaeeeeeees Piston Piston Rings and Piston Pin Piston Pin Bore I D Top Compression Ring to Groove Side Clearance Middle Compression Ring to Groove Side Clearance Top and Middle Compression Ring End Gap New Bore TOO ln e WE Middle RING BN Used Bore MIX VE Piston Thrust Face O D 2 SV470 SV480 Max Wear Limit eet Ste ee EE SV530 SV540 Max Wear Limit sscnccdeScccecsuanttaticunnvewssdnssdanerdaunedwmastenchiden SV590 SV600 VIS Max Wear Limit EE Piston Thrust Face to Cylinder Bore Running Clearance SV470 SV480 SV530 WE SE VIGI sereen eebe Rectifier Regulator Mounting ee e UTC Speed Control Speed Control Bracket Assembly Fastener Torque Section 1 Safety and General Information EEN 4 5 5 0 N m 40 46 in Ib RE 4 0 N m 85 in Ib e 0 165 0 315 mm 0 0065 0 0124 in eee 4 5 5 0 N m 40 45 in Ib Ee 22 006 22 012 mm 0 8685 0 8666 in ee 22 025 mm 0 86 71 in eee 21 995 22 0 mm 0 8659 0 8661 in SE 21 994 mm 0 8658 in Se 0 04
17. 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components 9 or 15 amp Battery Charging System Ground to Kill Lead T Ignition Key Switch Rectifier Regulator Violet Flywheel Red fe R SEH ry A a wae Green Fuse SCH ve Optional Connector Se Fuel Solenoid Optional ol ZC H Indicator Light Optional Oil Sentry ci Switch Shutdown 9 Optional Oil Sentry Switch Indicator O SS l Bendix Starter Starter Solenoid E Figure 7 9 9 or 15 amp Regulated Battery Charging System 7 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Rectifier Regulator 9 or 15 Amp Stator Figure 7 10 9 or 15 amp Stator and Rectifier Regulator DC Volt Meter Rectifier Regulator Flywheel Stator Battery Ammeter Figure 7 11 Proper Connection to Test 9 or 15 amp Charging System 7 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at full throttle no load The battery
18. 8 9 mm 0 350 in Nominal Valve Seat Angle ccccccccccccccsseceeeeeeeeeeeeeseeeeeeeeeeaeeeeeeeeeeeeeeeaas 45 Intake Valve Stem to Valve Guide Running CJearanmce 0 038 0 076 mm 0 0015 0 003 in Exhaust Valve Stem to Valve Guide Running Clearance 000cccee 0 050 0 88 mm 0 0020 0 0035 in Intake Valve Guide I D KE 6 038 6 058 mm 0 2377 0 2385 in Max Wear ELIA traces cuneate ota elanc Maneve ari dan baw nian cana tanuieuinnunt nean Seana 6 1385 mm 0 2415 in Intake Valve Stem Diameter KE 5 982 6 0 mm 0 2355 0 2362 in Exhaust Valve Guide I D KE 6 038 6 058 mm 0 2377 0 2385 in Max eg TE 6 160 mm 0 2425 in NOW A A 5 970 5 988 mm 0 235 0 2357 in 8Check valve lash every 200 hours adjust as required 1 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 10 Property Class Noncritical Fasteners Into Aluminum vn l 7 15 2 9 26 1 36 M5 GER Ai get 1 7 d M6 4 3 38 7 50 9 9 88 E 300 2 0 18 M8 10 5 93 e 6 120 24 4 216 33 9 Tightening Torque N m ft Ib or 10 Le Class SC Noncritical Fasteners Into Aluminum M10 d 7 16 We Ki 5 35 Zi 33 9 25 M12 36 6 27 47 5 ie 82 7 61 116 6 86 61 0 45 M14 558 3 E 76 4 Ge 131 5 ee 184 4 1 de 94
19. 9 70 Oil Drain Plugs Tightening Torque Nem English Equiv Torque Size Into Cast Iron Into Aluminum Conversions 1 8 NPT 4 5 40 in Ib el 1 4 17 0 150 in Ib 11 3 100 in Ib Wes S E 3 8 20 3 180 in Ib 13 6 120 in Ib 1 2 27 1 20 ft Ib 17 6 13 ft Ib 3 4 33 9 25 ft Ib 21 7 16 ft Ib X 708 1 27 1 33 9 20 25 ft Ib 27 1 33 9 20 25 ft Ib in lb Nem x 8 85 ft Ib N m x 0 737 1 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 2 Special Tools Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you can service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Kohler special tools are handled by SPX Corp a division of Owatonna Tool Corp OTC The tools are easy to purchase by contacting SPX OTC by phone fax or mail Phone 1 800 533 0492 Fax 1 800 578 7375 Mail SPX Corp OTC International 1 507 455 7223 1 586 578 7375 28635 Mound Hd 8 00 am 8 00 pm EST International 1 507 455 7063 Warren MI 48092 3499 Some special tools for this engine are Flywheel Eegeregie NU3226 WAIVE Guide FRE ACE sates et coe deel aiei a iaa i i KO1026 Rocker Arm Spanner Wrench cccccscccceseeccceeceeceeeseceeeeeeseeeessea
20. 9623 or 606 561 4983 Section 2 Special Tools Figure 2 2 Flywheel Holding Tool Rocker Arm Crankshaft Tool If you don t have a spanner wrench to lift the rocker arms or to turn the crankshaft you can make a tool for doing this out of an old junk connecting rod 2 2 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap If it is a Posi Lock rod you will also need to remove the studs If it is a Command rod you will need to grind off the aligning steps so the joint surface is flat Find a 1 long capscrew with the correct thread size to match the threads in the connecting rod Obtain a flat washer with the correct I D to slip on the capscrew and an O D of approximately 1 Kohler Part No 12 468 05 S can be used if you don t have the right size on hand Assemble the capscrew and washer to the joint surface of the rod as shown in Figure 2 3 Figure 2 3 Rocker Arm Crankshaft Tool www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common types of engine troubles are listed below Use these to help locate the possible cause s Engine Cranks But Will Not Start Empty fuel tank Fuel shut o
21. Disassemble removal tool Kohler Part No 25 761 18 S 2 Referring to Figure 7 12 grasp the spring retainer and push it toward the starter compressing the anti drift spring and exposing the retaining ring 3 Holding the spring retainer in the retracted position assemble the inner halves of the removal tool around the armature shaft with the retaining ring in the inner groove see Figure 7 13 Slide the collar over the inner halves to hold them in position Figure 7 13 Assembling Inner Half of Tool Around The Armature Shaft and Retaining Ring 4 Thread the center screw into the removal tool until you feel resistance Use a wrench 1 1 8 or adjustable to hold the base of the removal tool Use another wrench or socket 1 2 or 13 mm to turn the center screw clockwise see Figure 7 14 The resistance against the center screw will tell you when the retaining ring has popped out of the groove in the armature shaft Si eat i Af Ca w E Figure 7 14 Holding Tool and Turning Center Screw Clockwise to Remove Retaining Ring 5 Remove the drive components and drive nut collar from the armature shaft paying attention to the sequence If the splines are dirty clean them with solvent 6 The splines should have a light film of lubricant Relubricate as necessary with Kohler bendix starter lubricant Part No 52 357 01 S Reinstall or replace the drive components assembling them in the same sequence as they w
22. Figure 10 2 PTO Seal Depth Details Install Governor Cross Shaft 1 Place the thin thrust washer onto the governor cross shaft as far as it will go 2 Lightly lubricate the shaft with oil and install it from inside the crankcase See Figure 10 3 hin Washer Ce Governor Figure 10 3 Installing Governor Cross Shaft 3 Slide the thick thrust washer onto the shaft from the outside as far as it will go Secure by inserting the hitch pin in the machined groove See Figure 10 4 10 2 DH Figure 10 4 Securing Governor Shaft Install Oil Pump Assembly and Intake Cam Shaft 1 Ifthe oil pump assembly was removed from the intake cam shaft reassemble it onto the shaft The drive pin holes are machined to be a clearance slip fit on one side and a press fit on the other Support the cam shaft with the clearance holes up and install the shorter 2 5 mm 0 098 in diameter pin in the outer hole closest to the bottom end See Figure 10 5 and 10 6 Center the pin in the shaft Outermost Hole Figure 10 5 Installing Oil Pump and Lower Drive Pin on Intake Cam Shaft www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Figure 10 6 Assembled Intake Cam Shaft Details Intake Cam Shaft 3 mm Diameter Pin Oil Pump Assembly 2 5 mm Diameter Pin 1 Hole Location 2 Hole Location Ot E Jee 2 If it was removed install and center the longer
23. Pin 8 mm 0 314 in Figure 9 2 Cylinder Bore Crosshatch after Honing 4 After honing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements Figure 9 3 Measuring Piston Diameter The measurements should be taken at three locations in the cylinder at the top middle and 2 Use an inside micrometer telescoping gauge or bottom Two measurements should be taken bore gauge and measure the cylinder bore Take perpendicular to each other at each of the three the measurement approximately 63 5 mm locations 2 5 in below the top of the bore and perpendicular to the piston pin Clean Cylinder Bore after Honing Proper cleaning of the cylinder walls following honing 3 Piston to bore clearance is the piston diameter is critical Grit left in the cylinder bore can destroy an subtracted from the bore diameter step 2 minus engine in less than one hour of operation after a step 1 rebuild Balance Weight Assembly The final cleaning operation should always be a The balance weight assembly counterbalances the thorough scrubbing with a brush and hot soapy water crankshaft weights and internal forces during operation Use a strong detergent that is capable of breaking to minimize vibration Several key areas of the balance down the machining oil while maintaining a good level weight must be checked before installation and use of suds If the suds break dow
24. Reassembly 2 Move the governor lever toward the carburetor to the limit of its travel wide open throttle and hold in this position Do not apply excessive pressure flexing or distorting the linkage Grasp the cross shaft with a pliers and turn the shaft counterclockwise as far as it will go See Figure 10 64 Torque the hex nut to 7 0 8 5 N m 60 75 in Ib Counter Clockwise D Figure 10 64 Adjusting Governor and Linkage Mounting Speed Control Bracket 1 Attach the governor spring to the governor lever and the throttle lever of the speed control bracket in the original holes If the holes were not marked during disassembly refer to the chart in Section 5 Figure 5 23 Connect the choke linkage from the carburetor to the actuating lever of the speed control bracket See Figure 10 65 d Governor I Spring A Choke Linkage Figure 10 65 Connecting Choke Linkage and Governor Spring 10 18 2 Attach the speed control bracket to the mounting locations on the engine with the M6 screws Position the bracket as marked during disassembly Torque the screws to 11 0 N m 95 in Ib into new as cast holes or 7 5 N m 65 in Ib into used holes See Figure 10 66 Figure 10 66 Attaching Speed Control Bracket Install Fuel Pump if equipped 1 Attach the fuel pump mounting bracket to the speed control bracket with the two M5 screws Torque the screws to 6 5 N m 55 in Ib into new as cast holes
25. TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F 30 weight acceptable above 0 C 32 F Figure 6 1 Viscosity Grades Table NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 2 Sn Figure 6 2 Oil Container Logo Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it 3 Remove the oil fill cap dipstick wipe oil off Reinsert the dipstick into the tube and fully seat the dipstick in the tube See Figure 6 3 6 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 6 Lubrication System Figure 6 3 Removing Dipstick Figure 6 4 Dipstick Seated 4 Remove the dipstick and check the oil level The oil level should be up to but not over the F mark on the dipsti
26. errr eer ee eee ee eee ene een eee 535 cc 32 6 Cu in EE 597 cc 36 4 Cu in Compression Ratio ids cnmcascdivie saa csinnsssanoenuwbutednawadaesnhicegawaseteaudiiesunuipiandeedowenaiies 8 5 1 O WV O aaa a E EEE EEE E E EE 35 8 kg 79 Ib Oil Capacity with filter swascccpecatnedosiecsdenncasieaaadactaasniewtsleasenbicieddawacdneobeiaentdenyalecs 1 5 L 1 6 qt Angle of Operation Maximum at Full Oil Level All Directions 25 Intermittent Air Cleaner Base e Nut Fastener TOrgUe iicccnsarsevunsceumansaniocrnmeensuamnphasianuensyntaranmuinencthan 5 5 N m 48 in Ib Mounting Screw Fastener Torque Install Dry DO NOT OI 8 0 N m 70 in Ib Into new as cast hole 5 5 N m 48 in lb Into used hole Blower Housing and Sheet Metal MG Fasteners e TE 7 5 N m 65 in Ib Cam Lever Cam Lever Fastener Torque ccccccccseecceeeaeeeeeceeseeeeeeeesaeeeeeeeeeeeaeeeeesaeees 7 5 N m 65 in Ib Cam Gears nleh SE 0 5 1 5 mm 0 019 0 059 in R nNNO SIS CICA AN e 0 02 0 13 mm 0 001 0 005 in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly EXCEPT for air cleaner base thread forming screw install dry 1 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Cam Gears cont d Cam Gear to Cam Shaft Running Assembly nsessenenennnennn
27. in Closure Plate D Kl 44 965 44 990 mm 1 7703 1 7713 in MIG VACA EINE emgeet 45 016 mm 1 7723 in Flywheel End Main Bearing Journal 9 E EE 44 913 44 935 mm 1 7682 1 7691 in O D Max Wear E E 44 84 mm 1 765 in Max Taper E 0 0220 mm 0 0009 in Max Qut Of R ee 0 025 mm 0 001 in 1 8 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Crankshaft cont d PTO End Main Bearing Journal Eege 41 913 41 935 mm 1 6501 1 6510 in O D Max Wear mm 41 86 mm 1 648 in M LAO CM ee E yncheden dees E E 0 020 mm 0 0008 in Max E Of ROUNO DE 0 025 mm 0 001 in Crankshaft Bore in Closure Plate Running Clearance Kl 0 03 0 077 mm 0 0012 0 003 in Crankshaft Bore in Crankcase Running Clearance Kl 0 03 0 077 mm 0 0012 0 003 in Connecting Rod Journal O D Kl 40 982 41 000 mm 1 6134 1 6141 in Max Wear Limit snxcannceteitosedaonnatenoeyiantetiagoitaantstiakuptenunniccerambiaeanylauen 40 964 mm 1 612 in MPG E 0 012 mm 0 0005 in Max Qut Of e e 0 025 mm 0 001 in Crankshaft T I R PTO End Grankshatt in ENING E 0 15 mm 0 0059 in Entire Crankshaft in V BIOCKS ccccccsseseeeeeeeeeceeeeseeeeeeessaeaeees 0 10 mm 0 0039 in Crankshaft Eccentrics O D Kl 66 940 66 970 mm 2 6354 2 6366 in Max Et EE 66 89 mm 2 633 in Balance Weight Bearing Surface I D DVO scene sevice potest ne EEE 67 011 67 086 mm 2 6382 2 641
28. is designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plug no maintenance or timing adjustment is necessary or possible The ignition module automatically controls the timing of the spark Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help systematically determine the cause of a reported problem Reported ignition problems are most often due to poor or loose connections Before beginning the test procedure check all external wiring including ground leads for wiring harness and rectifier regulator if so equipped Be certain all ignition related wires are connected including the spark plug lead and all terminal connections fit snugly Make sure the ignition switch is in the run position ZA NOTE The CD ignition systems are sensitive to excessive load on the kill lead Customer complaints of hard starting low power or misfire under load may be due to excessive draw on the kill circuit Disconnect any auxiliary kill wires or safety switches connected to the kill circuit and operate the engine to determine if the reported problem is gone Preliminary Test To be certain the reported problem is in the engine ignition system it should be isolated from the unit as follows 1 Locate the plug connectors where the wiring harnesses from the engine and unit are joined Separate the connectors and sep
29. is turned off Never operate negative battery cable from the engine with heat shields or battery guards removed 1 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information A WARNING AA WARNING A E 2 Ae Carbon Monoxide can cause severe nausea fainting or death Explosive Fuel can cause fires and severe burns Stop engine before filling fuel tank Do not operate engine in closed or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fumes and never run the engine fill the fuel tank while the engine is in a closed building or confined hot or running since spilled fuel area could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AA WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of igni
30. mixture can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and poor or slow governor response To compensate for the effects of high altitude a special high altitude main jet can be installed High altitude jets are sold in kits which include the jet and necessary gaskets Refer to the Parts Manual for the engine being serviced for the correct kit number Unitized Throttle and Choke Control Some engines are equipped with a unitized throttle and choke control This assembly controls the choke and engine speed with a single lever See Figure 5 12 Throttle Cable Adjustment 1 Loosen the throttle control cable clamp See Figure 5 12 A Lh GRC Cage FLOW OIL FILTER Sc ABSO WITH Ci Nig ORE ae ORB oj LEAN OJ Ku Kb ymin 284 INCH Lag Figure 5 12 Speed Control Bracket with Unitized Throttle Choke Control 5 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor 2 Place the throttle control lever of the equipment into the fast or high speed position The actuating tab of the choke lever should be just below the end of the choke adjusting screw See Figure 5 13 Choke Adjustment Screw Figure 5 13 Adjusting Unitized Throttle Choke Control NOTE The choke is placed on by moving the throttle control slightly past the fast position If th
31. mm 0 0016 in SE 0 04 mm 0 0016 in ee 0 15 0 40 mm 0 006 0 016 in NEE 0 30 0 55 mm 0 012 0 022 in ere 0 77 mm 0 030 in EE 83 948 83 962 mm 3 3050 3 3056 in ee ee 83 828 mm 3 3003 in SE 88 948 88 962 mm 3 5018 3 5024 in SE 88 828 mm 3 4972 in EEN 93 928 93 942 mm 3 6980 3 6985 in eebe 93 828 mm 3 6940 in EE 0 0575 mm 0 0023 in Ee 0 0875 mm 0 0034 in SE 6 0 N m 55 in Ib Into new as cast hole 4 0 N m 85 in Ib Into used hole EE 11 0 N m 95 in Ib Into new as cast hole 7 5 N m 65 in Ib Into used hole Measure 8 mm 0 314 in above the bottom of the piston skirt at right angles to the piston pin www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Stator Stator MOUNTING Screw Ioroue sonnnnsnnnunsnnnnsnnnnrnrrnsenrrrennrenrrrrsenrresnn 6 0 N m 55 in Ib Into new as cast hole 4 0 N m 35 in Ib Into used hole Throttle Choke Controls Governor Control Lever Fastener Torque c ccsssesesceeceeceeeeeseeeeeeesnaeeees 7 0 8 5 N m 60 75 in Ib Valve Cover Valve Cover Fastener Torque 11 0 N m 95 in Ib Into new as cast hole 7 5 N m 65 in lb Into used hole Valves and Valve Lifters VAVO LO I E 0 076 mm 0 003 in Intake Valve Minimum Lift E 8 9 mm 0 350 in Exhaust Valve Minimum Lift scsuucsresncewiwinedinenanaunirrantolinavenninswnnunanaidiewinetawiy
32. models so equipped 1 Remove the hex flange nuts from the exhaust 1 Disconnect the lead from the Oil Sentry studs If a muffler bracket is used remove the hex flange screws attaching the muffler or pressure switch exhaust system to the bracket 2 Remove the pressure switch from the center See Figure 8 2 port studs See Figure 8 4 Figure 8 2 Removing Oil Sentry Switch Figure 8 4 Removing Exhaust Flange Nuts Remove Blower Housing Remove Rectifier Regulator 1 Remove the four shoulder screws securing the 1 Unplug the connector from the rectifier regulator blower housing to the closure plate Figure 8 3 2 Remove the two screws securing the rectifier 2 Lift the blower housing and separate the spark regulator to the crankcase Remove the rectifier plug lead from the corresponding slot regulator See Figure 8 5 AN LOWOINny MISA NOSNHOr Dan Ul palquassy JON LORENZ Figure 8 5 Removing Rectifier Regulator Figure 8 3 Removing Blower Housing Screws Disconnect Spark Plug Lead Remove Electric Starter 1 Carefully pull on the boot section and disconnect 1 Disconnect the starter lead from the terminal stud the spark plug lead 2 Remove the two hex flange nuts securing the starter to the closure plate Remove the starter See Figure 8 6 8 2 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 gene L in gen f Figure 8 6 Removing Electric Start
33. module as far from the flywheel as possible Tighten the hex flange screws sufficiently to keep the module in position See Figure 10 48 i AAN A a Figure 10 48 Installing Ignition Module 2 Rotate the flywheel to align the magnet with the ignition module 3 Insert a 0 25 mm 0 010 in flat feeler gauge between the magnet and ignition module See Figure 10 49 Loosen the screws so the magnet pulls the module against the feeler gauge 10 14 Figure 10 49 Setting Air Gap 4 Torque the two screws to 6 0 N m 55 in Ib into new as cast holes or 4 0 N m 35 in Ib into used holes 5 Rotate the flywheel back and forth checking for clearance between the magnet and ignition module Make sure the magnet does not strike the module Recheck the air gap with a feeler gauge and readjust if necessary Final Air Gap 0 203 0 305 mm 0 008 0 012 in 6 Connect the kill lead to the tab terminal on the ignition module 7 If equipped with a sheathed RFI suppression spark plug lead place the lead in retaining clip so braided wires will be in direct contact with clip when closed Carefully close the clip with a pliers until a 0 127 mm 0 005 in gap exists between the ends Do not pinch or flatten the clip See Figure 10 50 ECH Ke Se e m P s ZS Se mm A SE C Dee CS i Figure 10 50 Tightening Clip around Sheathing www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606
34. of a fitting to the 8 o clock position 2 Ifa fitting is used connect the fuel pump pulse line and secure with the clamp See Figure 10 44 Pulse Line T e fi II Wy Se Ze WII WW HHN diii AA d f Le A i d N Eege Figure 10 44 Connecting Pulse Line to Fitting www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Install Fan and Flywheel 4 Install the fan mounting plate onto the fan aligning the four cutouts followed by the heavy A WARNING Damaging Crankshaft and flat washer and hex flange screw See Figure 10 45 Flywheel can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and completely free of lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the mounting screw is torqued to specification Figure 10 45 Installing Fan and Mounting NOTE Make sure the flywheel key is installed Hardware to Flywheel properly in the keyway The flywheel can become cracked or damaged if the key is not
35. or damaged Since the air cleaner base and carburetor are secured to the intake port with common hardware it is extremely important that the fasteners securing these components are tight at all times The air cleaner base also provides the mounting points for the air cleaner cover retaining studs Make sure the bosses are not cracked broken or damaged and the studs are properly secured Before reinstalling an air cleaner base that has been removed make sure the metal bushings in the base mounting holes are present See Figure 4 2 The bushings prevent damage to the base and maintain the proper mounting torque Figure 4 2 Bushings in Air Cleaner Base Breather Hose Make sure the hose is not cracked or damaged and attached to both the air cleaner base and valve cover NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Figure 4 3 Breather Hose Disassembly The following procedure is for complete disassembly of all air cleaner components As the removal of the air cleaner base also affects carburetor mounting and governor adjustment steps 3 and 4 should only be performed if required Detailed photos are provided in Sections 5 8 and 10 for the various individual steps 1 Loosen the air cleaner cover r
36. screen and other external surfaces Dirt or debris on these areas can cause overheating e Check for obvious oil leaks and damaged components Excessive oil leakage can indicate a clogged or inoperative breather worn or damaged seals or gaskets or loose fasteners e Check the air cleaner cover and base for damage or indications of improper fit and seal e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate improper maintenance 3 2 e Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner was not functioning properly e Check if the oil level is within the operating range on the dipstick If it is above sniff for gasoline odor e Check the condition of the oil Drain the oil into a container it should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate the wrong type or weight of oil was used the oil was not changed at the recommended intervals an over rich fuel mixture or weak ignition to name a few possible causes NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After in
37. started with spark plugs that are worn or fouled Engines without ACR would be less likely to start with the same plugs Cam Gears Inspection and Service Inspect the gear teeth and cam lobes of the intake and exhaust cam gears If the lobes exhibit excessive wear or the teeth are worn chipped or broken replacement of the cam gear s will be necessary Crankshaft and Crank Gear Inspection and Service Inspect the teeth of the crank gear If the teeth are badly worn chipped or some are missing replacement of the crank gear will be necessary Remove the gear by pulling it off the key and crankshaft Inspect the crankshaft bearing journal surfaces for wear scoring grooving etc If they show signs of damage or are out of running clearance specifications the crankshaft must be replaced Inspect the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for wear score marks or aluminum transfer Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits are exceeded see Section 1 it will be necessary to replace the crankshaft 9 2 Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments and deep scratches or nicks Check the cylinder wall for scoring In severe cases unburned fuel can wash the necessary lubricating oil off the piston and cylinder wall The piston rings make metal to me
38. stator or diode are probably faulty Test the stator and diode Test 2 3 and 4 2 Disconnect the charging lead from battery 2 If voltage is 20 volts or more stator winding is OK With engine running in the fast setting measure voltage from charging lead to If voltage is less than 20 volts test stator ground using a DC voltmeter using an ohmmeiter Tests 3 and 4 3 With charging lead disconnected from 3 If resistance is low in both directions the battery and engine stopped measure diode is shorted Replace the diode resistance from charging lead to ground No using an ohmmeter Note reading If resistance is high in both directions the Charge diode or stator winding is open Use To Reverse the leads and measure resistance Test 4 Battery again In one direction the resistance should be infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on Rx1 range 4 Cut the sleeving on the charging lead to 4 lf resistance is approximately 0 5 ohms expose the diode connections Stator winding is OK diode is open Replace diode Measure the resistance from the stator side of diode to ground using an ohmmeter If resistance is 0 ohms stator winding is shorted Replace stator If resistance is infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the lighting lead from th
39. the two balance weight halves together on the crankshaft Hold the guide pin with a wrench if required See Figure 8 50 Figure 8 52 Removing Hitch Pin and Washer 2 Slide the shaft inward and remove it through the inside of the crankcase Be careful not to lose the small washer in the inside portion of the shaft See Figure 8 53 e Figure 8 50 Removing Balance Weight Screw 4 Mark the weights for proper reassembly and carefully slide the balance weights off the crankshaft eccentrics See Figure 8 51 Figure 8 53 Removing Governor Cross Shaft Figure 8 51 Disassembled Balance Weight 8 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Remove PTO and Flywheel Side Oil Seals 1 Use a seal puller to remove the PTO and flywheel side oil seals See Figure 8 54 Figure 8 54 Removing Seal with a Seal Puller 8 14 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 9 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Air Cleaner Section 4 Carburetor amp External Governor Section 5 Ignition Charging amp Electric Starter Section 7 Clean all parts thoroughly Only clean parts can be
40. the slot in the choke shaft Make sure the choke shaft is locked between the tabs on the choke plate 5 8 Welch Plug Installation Use SPX Tool No KO1017 and install new plugs as follows 1 Position the carburetor body with the welch plug cavities to the top 2 Place anew welch plug into the cavity with the raised surface up 3 Use the end of the tool that is about the same size as the plug and flatten the plug Do not force the plug below the surface of the cavity See Figure 5 9 Tool No KO1017 Carburetor Body 4 pew CLEN EUG Figure 5 9 Installing Welch Plugs 4 After the plugs are installed seal them with Glyptal or an equivalent sealant Allow the sealant to dry NOTE Ilfacommercial sealant is not available fingernail polish can be used Carburetor Reassembly 1 Install the low idle speed adjusting screw and spring 2 Ifthe low idle fuel adjusting needle contains a limiter adjust to the midpoint within the adjustment range 3 Insert the fuel inlet needle into the float Align the needle with the seat and lower the float into the carburetor body See Figure 5 10 Install the float shaft www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Figure 5 10 Installing Float and Fuel Inlet Needle 4 Install the bowl gasket fuel bowl bowl retaining screw gasket and bowl retaining screw or fuel solenoid Torque the bowl retaining screw to 5 1 6 2 N
41. valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 003 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance Maximum 1 D wear on the intake valve guide is 6 135 mm 0 2415 in while 6 160 mm 0 2425 in is the maximum allowed on the exhaust guide The guides are not removable If the guides are within limits but the valve stems are worn beyond limits replace the valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable but they can be reconditioned if not too badly pitted or distorted If the seats are cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 9 11 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 9 10 With the proper 45 valve face angle and the valve seat cut properly 44 5 as measured from centerline when cut 89 this would result in the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the valve face and seat Section 9 Inspectio
42. 0 36 torque the cylinder head screws in two stages initially to 20 5 N m 180 in Ib and finally to 41 0 N m 360 in Ib 4 Install a new cylinder head gasket See Figure 10 34 a J Figure 10 36 Cylinder Head Fastener Torque Sequence Install Rocker Arms and Push Rods NOTE Installation and seating of the push rods into the cam lever recesses during this sequence is Critical Position the engine with the cylinder head up if possible to aid with Figure 10 34 Installing Head Gasket proper installation of the push rods and rocker arms and adjusting the valve lash 5 Install the cylinder head and start the six hex flange screws Install the thick washer on the 1 Position the push rod guide plates on the cylinder screw closest to the exhaust port See Figure head with the extruded edges down over the 10 35 push rod bores Secure by installing the rocker arm pivot studs Torque the studs to 13 5 N m 120 in Ib See Figure 10 37 10 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Figure 10 37 Installing Guide Plates and Rocker Arm Pivot Studs 2 Apply grease to the contact surfaces of the rocker arms and adjusting nuts and install them onto the pivot studs NOTE If being reused push rods should always be installed in their original position 3 Note the mark or tag identifying the push rod as either intake or exhaust Appl
43. 06 561 4983 Section 10 Reassembly 3 32 Allen Wrench Figure 10 10 Checking Outlet Seal Passage Opening Open Style Figure 10 11 Torquing Oil Pump Mounting Screws Install Crankshaft and Balance Weight 1 Assemble the crankshaft balance weight if removed from the crankshaft a Lubricate the crankshaft eccentrics and the balance weight bearing surfaces with oil b Install the two balance weight halves onto the crankshaft eccentrics as marked or originally installed c Align the weights and install the balance weight screw through the mounting holes from the PTO side Thread it into the guide pin outside the weight on the flywheel side Hold the guide pin with a wrench and torque the screw to 10 N m 90 in Ib See Figure 10 12 Do not hold or damage the outside diameter O D of the guide pin 10 4 Guide Pin Figure 10 12 Assembling Balance Weight to Crankshaft d Carefully install crank gear key in keyway See Figure 10 13 Crank Gear Key Figure 10 13 Installing Crank Gear Key 2 Lubricate the PTO end bearing surfaces of the crankshaft and crankcase with oil Apply a small amount of oil or grease to the lips of the PTO oil seal and to the guide shoe pin Cover PTO keyway with tape to prevent cutting oil seal during installation 3 Carefully install the crankshaft into the crankcase through the PTO seal and seat fully into place Rotate the crankshaft so that the journal f
44. 1 Clean the exterior surfaces of the engine 4 Due to the deep recess around the spark plug blow out the cavity with compressed air Remove 2 Change the oil and oil filter while the engine is stil the spark plug The spark plug is most accessible warm from operation See Change Oil and Oil when the blower housing is removed for cleaning Filter in Section 6 Add one tablespoon of engine oil into the spark 3 The fuel system must be completely emptied or plug hole Install the plug but do not connect the the gasoline must be treated with a stabilizer to plug lead Crank the engine two or three prevent deterioration If you choose to use a revolutions Connect the plug lead stabilizer follow the manufacturer s recommendations and add the correct amount 5 Reinstall the blower housing if removed for the capacity of the fuel system Fill the fuel previously and torque the blower housing screws tank with clean fresh gasoline Run the engine for to 7 5 N m 65 in Ib 2 3 minutes to get stabilized fuel into the carburetor 6 Store the engine in aclean dry place 1 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information b 302 48 ae 35 72 i EE e 11 909 1 406 Dimensions in millimeters Inch equivalents shown in 63 33 pH FUEL PUMP 2 493 OPTIONAL 1 AIR FILTER T AND COVER THROTTLE CABLE CLIP
45. 10 30 If the wiring harness was separated from engine oil including the tips of the valve stems and the closure plate route the harness through the valve guides Using a valve spring compressor install clamps and the slot in the closure plate Close the following items in the order listed See Figure the clamps to retain the harness 10 32 5 Torque the closure plate fasteners to 24 5 N m e Intake and exhaust valves 216 in Ib using the sequence shown in Figure e Valve spring caps 10 31 e Valve springs e Valve spring retainers e Valve spring keepers Figure 10 32 Assembling Cylinder Head Install Cylinder Head NOTE Do not reuse cylinder head screws or gasket always replace with new parts 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase 10 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly IMPORTANT 2 If the crankshaft has not been turned since the installation of the crank gear turn it one 1 complete revolution This will set the piston at top dead center TDC of the compression stroke for proper valve lash adjustment later Washer 3 Install the drain back check ball into the keyhole Me et Position 6 slot in the top of the crankcase See Figure 10 33 ZE f A i Figure 10 35 Installing Cylinder Head Fasteners 6 Using the torque sequence shown in Figure 1
46. 2 in Max Wear UTI E 67 140 mm 2 6430 in Balance Weight Screw Ioroue ssnaannnnnennnnnnennnnnennnnnnsnnrnnnsnnrennsnnneenne 10 0 N m 90 in Ib Guide Pin O D VIE 11 950 11 975 mm 0 4705 0 4715 in Max Wear E UN 11 900 mm 0 4685 in Guide Shoe Width EE 17 85 17 90 mm 0 703 0 705 Max Wear Limit cccneancenanbtamencasguxtanienisanbentnntasroaniniasant comin tiaaniinatoets 17 75 mm 0 6988 in Guide Shoe Hole I D Ee 12 000 12 025 mm 0 4724 0 4734 in Max Wear IMI GE 12 050 mm 0 4744 in Cylinder Bore Cylinder Bore I D New SEET ME 84 000 84 025 mm 3 307 3 308 in SEET DE 89 000 89 025 mm 3 504 3 505 in I OO eege 94 010 94 035 mm 38 701 3 702 in Max Wear Limit FO WE 84 073 mm 3 310 in STE OR E E E 89 073 mm 3 507 in SVI OO NH 94 073 mm 3 704 in 1 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Cylinder Bore I D cont d MWK e 0 05 mm 0 002 in Max Ieren LEE 0 12 mm 0 0047 in Cylinder Head Cylinder Head Fastener Torque torque in 2 increments nnn00nnn000nnn 20 5 41 0 N m 180 360 in Ib Max Out of FlatneSs cccccccccssseceeceeeeecseeececeeeeecssaeeesseaeeesseuseessaaeess 0 8 mm 0 003 in Rocker Arm Pivot Stud Torque ccccccccseeeeeeeeeeeeeceeeseeeeeeeeesaaaeeeeeseaaees 13 5 N m 120 in Ib Rocker Arm Adjustment Nut Set SCrew cccccccccssseeeeeeeeeesee
47. 5 Use a flywheel strap wrench or holding tool to properly installed hold the flywheel Torque the hex flange screw to 66 5 N m 588 in Ib See Figure 10 46 NOTE Always use a flywheel strap wrench or flywheel holding tool to hold the flywheel when tightening the flywheel fastener Do not use any type of bar or wedge between the cooling fins or flywheel ring gear as these parts could become cracked or damaged 1 Install the woodruff key into the crankshaft keyway Make sure that the key is fully seated and parallel with the shaft taper 2 Install the flywheel onto the crankshaft aligning the keyway with the key Be careful not to shift or unseat the key E e Figure 10 46 Torquing Flywheel 3 Position the fan onto the flywheel so the locating pins drop into the corresponding recesses 10 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Install Electric Starter 1 Install the electric starter to the closure plate and secure with the two 10 24 hex nuts Make sure the wires are clear of any moving parts and torque the hex nuts to 3 6 N m 32 in Ib See Figure 10 47 Figure 10 47 Installing Electric Starter Install Ignition Module 1 Rotate the flywheel so the magnet is away from the ignition module bosses Using the hex flange screws install the ignition module to the crankcase bosses with the kill terminal up Move the
48. 561 4983 Install New Spark Plug 1 Use anew Champion RC12YC or QC12YC or equivalent spark plug 2 Set the gap to 0 76 mm 0 030 in 3 Install the spark plug and torque it to 24 30 N m 18 22 ft Ib See Figure 10 51 Figure 10 51 Installing Spark Plug 4 Connect the spark plug lead Install Heat Deflector Carburetor Linkage and Air Cleaner Base 1 If the carburetor mounting stud was removed reinstall it in the outer cylinder location closest to head Use an E5 Torx socket or two hex flange nuts tightened together and turn the stud in until tight See Figure 10 52 Figure 10 52 Mounting Stud Installed 2 Make sure all the gasket surfaces are clean and free of any nicks or damage Section 10 Reassembly 3 Install a new intake gasket onto the carburetor stud then install the heat deflector The curved section should be down toward the engine with the protruding point on the back inserted into the intake port Be sure the protruding point goes through the large hole in the gasket to keep it aligned See Figure 10 53 UE Ch Figure 10 53 Installing Intake Gasket and Heat Deflector 4 Models with one screw and one mounting stud only Insert a 3 16 diameter rod approximately 4 long into the open mounting hole in the heat deflector to serve as a temporary alignment pin See Figure 10 54 Be careful not to force the rod or damage the threads Figure 10 54 Insert
49. 6 561 4983 Section 5 Fuel System and Governor e Throttle plate choke plate throttle shaft and choke shaft NOTE Do not submerge the carburetor in cleaner or solvent when plastic fiber rubber foam seals or gaskets are installed The cleaner may damage these components Inspection Carefully inspect all components and replace those that are worn or damaged e Inspect the carburetor body for cracks holes and other wear or damage e Inspect the float for cracks holes and missing or damaged float tabs Check the float hinge and pin for wear or damage e Inspect the fuel inlet needle and seat for wear or damage e Inspect the tip of the low idle fuel adjustment needle for wear or grooves e Inspect the throttle and choke shaft and plate assemblies for wear or excessive play Repair Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits are ordered Reassembly Choke Shaft Installation 1 Install the choke return spring to the choke shaft 2 Insert the choke shaft with the return spring into the carburetor body 3 Rotate the choke lever approximately 1 2 turn counterclockwise Make sure the choke return spring hooks on the carburetor body 4 Position the choke plate as marked during disassembly Insert the choke plate into
50. 83 Section 5 Fuel System and Governor 2 While observing the choke link move the throttle control lever to the low idle slow position then back to full throttle fast The choke link should not move as the throttle moves through the normal range If it does back the adjusting screw out until it no longer moves 3 Move the throttle control lever to the choke position Check if the choke has fully closed by placing your finger on the right side of the lower end of the choke lever choke link and applying gentle pressure towards the carburetor If the controls have been properly set the link should not move Separate Throttle and Choke Control Some engines are equipped with separate throttle and choke controls This allows you to adjust the choke and throttle controls individually Install Separate Control Cables See Figure 5 18 Throttle Control Installation 1 Loosen the two cable clamp screws on the speed control bracket assembly 2 Move the application throttle control lever to the maximum full fast throttle position and then move it back 3 16 or 4 75 mm Insert the cable boden wire into the throttle control lever on the control plate 3 Position the throttle cable under the cable clamp 4 Pull on the throttle cable until it stops hold it and tighten the cable clamp screw 5 Move the application throttle lever to the slow position then to full throttle Check the engine control to ensure it stops again
51. 983 Section 10 Reassembly 3 Torque the valve cover screws to 11 0 N m 95 in Ib into new as cast holes or 7 5 N m 65 in Ib into used holes using the sequence shown in Figure 10 41 Figure 10 41 Valve Cover Torque Fastener Sequence Install Stator and Wiring Harness Install Stator 1 Position the stator onto the mounting bosses so that the leads lay in the channel and recess of the closure plate See Figure 10 42 They will become captured when the blower housing is installed 2 Install the two hex flange screws to secure the stator and torque to 6 0 N m 55 in Ib into new as cast holes or 4 0 N m 35 in Ib into used holes Sipe Channel Figure 10 42 Installing Stator 10 12 Install Wiring Harness 1 Check that the locking tang on the terminal of the violet B wiring harness lead is angled upward Insert the terminal into the center location of the rectifier regulator plug connector until it locks into place If not already inserted the two AC leads from the stator go in the outer locations See Figure 10 43 Figure 10 43 Installing B Lead into Connector Install Pipe Plug or Fitting and Pulse Line for Fuel Pump 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the 1 8 pipe plug or 90 fitting as equipped Install and tighten into the tapped vacuum port of the closure plate Torque the plug to 4 5 5 0 N m 40 45 in Ib Turn the outlet
52. HLER CO KOHLER WISCONSIN 53044 0 87206 98614 7 www mymowerparts com
53. Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SERVICE MANUAL COURAGE SERIES SV470 600 VERTICAL CRANKSHAFT KOHLER lm ISS www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Contents Section 1 Safety and General Information cccceseeeeeeeeeeeeeeseecnneseseesensenenseseaneeenesens Section 2 Special TOOIS cccsccccesecceneecesseeceneeceseesensesenseeceasecensesoaseseasseeoseseasenenssoenessoneeses Section 3 Troubleshooting 2 cccccceeeseeceeeecensesenseneseeeensecensecoaseeeasescoasesoasesonseeoanssonseesensenes Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Electrical System and Components Section 8 Disassembly Section 9 Inspection and Reconditioning Section 10 REASSEMDIY ccceeeeeeseceeneeeeneecenseeceneeceseeseaseeeasecoaseecessecansesoasesoaseseanssoenesonseeses www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING W
54. accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Use gasket remover to remove old material from the valve cover cylinder head crankcase and oil pan Do not scrape the gasket surfaces as this could cause damage that results in leaks Make sure all traces of cleaning solvents are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Refer to A Guide to Engine Rebuilding TP 2150 for additional information Measurement Guide TP 2159 A and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR When the engine is stopped the spring returns the This engine is equipped with an Automatic flyweight contro pin assembly to the compression Compression Release ACR mechanism The ACR release position ready for the next start lowers compression at cranking speeds to make starting easier Operation The ACR mechanism consists of an actuating spring i Control Pin and a pivoting flyweight control pin assembly located Lt bk Lower Section in the exhaust side cam gear A thrust washer and mounting of the closure plate hold the ACR in positi
55. and any other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure all parts are reinstalled Torque the M6 blower housing fasteners to 7 5 N m 65 in Ib NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating 4 4 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 5 Fuel System and Governor Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to insure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave ro
56. and carburetor jet carburetor See Figure 5 2 The carburetors will are securely fastened to the engine using gaskets have a low idle speed adjustment screw and either in good condition fixed idle or a limiter cap on the idle fuel adjustment needle e Make sure the air cleaner element is clean and all air cleaner components are fastened securely e Make sure the ignition system governor system exhaust system and throttle and choke controls are operating properly If after checking the items listed above starting problems or conditions similar to those listed in the following table exist it may be necessary to adjust or service the carburetor Figure 5 2 Carburetor A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 5 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Troubleshooting Fuel System Possible Cause Probable Remedy 1 Engine starts hard runs roughly or Low idle fuel mixture speed improperly adjusted Adjust the low idle Stalls at i
57. and choke return spring Figure 5 7 Marking Choke Plate and Carburetor Body Section 5 Fuel System and Governor 2 The choke plate is inserted into a slot in the choke shaft Grasp the choke plate with pliers and pull it out of the slot See Figure 5 8 Figure 5 8 Removing Choke Plate 3 Remove the choke shaft and choke return spring Throttle Shaft Removal Do not attempt to remove the throttle shaft as repair kits are not available Throttle shaft wear is normally accompanied by corresponding wear to the carburetor body making it impractical to attempt a cost effective repair Replace the entire carburetor if the throttle shaft is worn Cleaning A WARNING Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent All parts should be cleaned thoroughly using a commercial carburetor cleaner Make sure all gum deposits are removed from the following areas e Carburetor body and bore especially the areas where the throttle plate choke plate and shafts are seated e Idle fuel and idle ports in carburetor bore main jet bowl vent and fuel inlet needle and seat e Float and float hinge e Fuel bowl 5 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 60
58. arate the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a Ifthe problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b Ifthe problem persists continue with the following troubleshooting procedure Leave the kill lead isolated until all testing is completed www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components CD Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems 1 Make sure the spark plug lead is connected to the spark plug 2 Check the condition of spark plug Make 2 If plug is in good condition check adjust sure gap is set to 0 76 mm 0 030 in gap and reinstall 3 a Test for spark with ignition tester SPX No 3 If visible and audible sparks are produced KO1046 Disconnect spark plug lead the ignition module is OK and connect it to the post terminal of the If visible and audible sparks are not tester See Figure 7 4 Connect the clip produced EE a PING a Make sure the engine ignition switch NOTE To maintain engine speeds kill switch or key switch is in the run normally obtained during position cranking do no
59. arings crankshaft connecting rod bearing surfaces cam gears and axis shafts An integral pressure relief valve within the oil pump limits the maximum pressure of the system For a cold engine at start up the oil pressure can go up to 20 25 psi For a warm normal operating temperature engine at idle speed the oil pressure can go down to 5 psi Service The oil pump rotors typically require no servicing if normal maintenance is performed as outlined in Section 1 The closure plate must be removed for access to the oil pump and the rotors Refer to the Disassembly and Reassembly Sections 8 and 10 for removal and reinstallation procedures Figure 6 7 Oil Pump on Intake Cam Shaft Gerotors Removed from Pump Housing Oil Filter These engines are equipped with a full flow oil filter See Figure 6 8 The oil filter helps remove sludge and other combustion by products from the oil It also extends the oil change interval and cools the oil Oil Filter Figure 6 8 Oil Filter Location Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure monitor If the oil pressure gets low Oil Senitry will either activate a low oil warning light or stop the engine depending on the application Operation The pressure switch is designed to break contact as the oil pressure increases and make contact as the oil pressure decreases At oil pressure above approximately 2 to 5
60. arning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others WARNING AA WARNING WARNING Accidental Starts can cause Rotating Parts can cause severe Hot Parts can cause severe burns severe injury or death injury Do not touch engine while operating Disconnect and ground spark plug Stay away while engine is in or just after stopping leads before servicing operation Accidental Starts Rotating Parts Hot Parts Disabling engine Accidental Keep hands feet hair and Engine components can get starting can cause severe injury clothing away from all moving extremely hot from operation To or death Before working on the parts to prevent injury Never prevent severe burns do not engine or equipment disable the operate the engine with covers touch these areas while the engine as follows 1 Disconnect the shrouds or guards removed engine is running or immediately spark plug lead s 2 Disconnect after it
61. cal System and Components Insert the armature into the starter frame The magnets will hold it in place See Figure 7 19 Figure 7 19 Armature Installed in Starter Frame Align the holes with the spaces between the magnets and install the drive end cap onto the front of the frame If the brush assembly is not being replaced position the springs and brushes within their pockets in the carrier move them to the retracted position and install carton staples to retain them See Figure 7 20 Replacement brushes come pre assembled in the carrier housing retained with two carton staples Figure 7 20 Brush Carrier Assembly with Staples 7 17 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components 5 Hold the brush holder assembly with the positive brush lead stud up Align the molded sections with the corresponding cutouts in the starter frame and slide the brush carrier assembly into place The commutator will push the carton staples out as the brush assembly is inserted See Figure 7 21 Figure 7 21 Installing Brush Carrier Using Staples 6 Position the commutator end cap over the brush assembly aligning the holes for the stud terminal and the thru bolts 7 Install the thru bolts and hex nuts Torque to 3 3 3 9 N m 30 35 in Ib See Figure 7 22 Figure 7 22 Torquing Thru Bolts 7 18 Install the insulating washer a
62. ce the flywheel if the ring gear is damaged Figure 9 8 Measuring Guide Pin O D 4 Use a split ball gauge or dial calipers and measure the I D of the corresponding hole in the guide shoe See Figure 9 9 Record these dimensions Ss Figure 9 9 Measuring Guide Shoe Hole I D 9 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seats for evidence of deep pitting cracks or distortion Check the running clearance between the valve stems and guides See Figure 9 10 for valve details and specifications Intake Valve Seat Angle Insert O D Guide Depth Guide D Valve Head Diameter Valve Face Angle Valve Margin Min Valve Stem Diameter Figure 9 10 Valve Details A B C D E F G H 9 6 www mymowerparts com pn Ba g j Ld gt a fp pl Ze ABS CM SC Insert Intake EI z Hl We Insert i j h 41 737 41 783 mm 10 20 mm 6 038 6 058 mm 37 625 37 375 mm 45 1 5 mm 5 982 6 000 mm Exhaust 36 237 36 263 mm 10 20 mm 6 038 6 058 mm 32 125 32 375 mm 45 1 5 mm 5 970 5 988 mm Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning
63. ck See Figure 6 5 Operating Range Figure 6 5 Oil Level Dipstick 5 Ifthe level is low add oil of the proper type up to the F mark on the dipstick Always check the level with the dipstick before adding more oil 6 2 NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Change Oil and Oil Filter Change the oil and oil filter annually or every 100 hours of operation Change the oil and oil filter while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling or checking oil Change the oil and filter as follows see Figure 6 6 Always use a genuine Kohler oil filter Oil Filter Oil Drain Plug Figure 6 6 Oil Drain Plug Oil Filter 1 To keep dirt grass clipping etc out of the engine clean the area around the oil fill cap dipstick before removing it 2 Remove the drain plug and oil fill cap dipstick Be sure to allow ample time for complete drainage 3 Remove the old filter and wipe off the mounting pad 4 Reinstall the oil drain plug and torque to 14 N m 125 in Ib 5 Place the new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bo
64. ct the lighting lead yellow from the wiring harness Measure the resistance from the lighting lead to ground using an ohmmeter 1 Make sure lights are not burned out Disconnect the lighting lead yellow from the wiring harness With engine running in the fast setting measure voltage from lighting lead to ground using an AC voltmeter With engine stopped measure the resistance of stator from lighting lead to ground using an ohmmeter No Lights Disconnect the charging lead black from Reverse the leads and measure resistance In one direction the resistance should be infinity ohms open circuit With the leads measured about midscale on Rx1 range 1 If voltage is more than 12 5 volts charging system is OK If voltage is 12 5 volts or less the stator or diode are probably faulty Test the stator and diode Test 2 3 and 4 If voltage is 5 volts or more stator winding is OK 2 If voltage is less than 5 volts test stator using an ohmmeter Tests 3 and 4 3 If resistance is low in both directions the diode is shorted Replace the diode If resistance is high in both directions the diode or stator winding is open Use Test 4 4 Ifresistance is approximately 0 15 ohms stator winding is OK diode is open Replace diode If resistance is 0 ohms stator winding is shorted Replace stator If resistance is infinity ohms stator winding or lead is open Replace stator 1 Rep
65. dable e An electronic capacitive discharge ignition electronic capacitive discharge CD ignition system module which mounts on the engine crankcase The system consists of the following components e Aspark plug e Amagnet assembly which is permanently affixed to the flywheel e Akill switch or key switch which grounds the module to stop the engine 7 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Figure 7 3 Capacitive Discharge Ignition Module Operation As the flywheel rotates and the magnet passes the ignition module the magnetic field induces current in the input coil L1 The current pulse is rectified by a diode D1 and charges a high voltage capacitor C1 As the magnet completes its pass it induces current in a small triggering coil L2 which turns on the semiconductor switch SCS With the switch on the charged capacitor is directly connected to the primary winding P of the transformer 11 As the capacitor discharges through the primary the current initiates a fast rising flux field in the transformer core The flux field induces a high voltage in the secondary winding S of the transformer The high voltage pulse is delivered to the spark plug where it arcs across the electrode gap and ignites the fuel air mixture in the combustion chamber Troubleshooting and Testing CD Ignition Systems The CD ignition system
66. dle speed speed screw then adjust the low idle fuel needle Improper choke adjustment Engine runs rich Indicated by Choke partially closed during operation Check the choke lever black sooty exhaust smoke linkage to ensure choke is operating properly misfiring loss of speed and power Low idle fuel mixture is improperly adjusted Adjust low idle fuel governor hunting or excessive needle throttle opening Float level is set too high With fuel bowl removed and carburetor inverted the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body Dirt under fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove fuel bowl low idle fuel adjusting needle and welch plugs Clean vent ports and air bleeds Blow out all passages with compressed air Fuel bowl gasket leaks Remove fuel bowl and replace gasket Leaky cracked or damaged float Submerge float to check for leaks Engine runs lean Indicated by Low idle fuel mixture is improperly adjusted Adjust low idle fuel misfiring loss of soeed and power needle governor hunting or excessive Float level is set too low With fuel bowl removed and carburetor throttle opening inverted the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body Idle holes plugged dirt in fuel delivery channels Remove fuel bowl low idle fuel adjusti
67. e dipstick Figure 10 79 Installing Oil Filter 10 21 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure the following have been done 1 All hardware is tightened securely 2 Theoil drain plug Oil Sentry pressure switch if SO equipped and a new oil filter are installed 3 The crankcase is filled with the correct amount weight and type of oil 10 22 Testing the Engine lt is recommended that the engine be operated ona test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Install an oil pressure gauge Start the engine and check to be certain that oil pressure 5 psi or more is present 2 Runthe engine for 5 10 minutes between idle and mid range Adjust the throttle and choke controls and the high speed setting as necessary Make sure the maximum engine speed does not exceed 3300 RPM Adjust the carburetor idle fuel needle and or idle speed screw as necessary Refer to the Fuel System and Governor section www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 KOHLER i angines E MAILED 10 03 LITHO IN U S A FOR SALES AND SERVICE INFORMATION U N IN U S AND CANADA CALL 1 800 544 2444 1PTP 2548 ENGINE DIVISION KO
68. e PTO end of the crankshaft is accessible Slide the holding tool onto the crankshaft align the slot with one of the mounting holes on the PTO face and tighten it onto the crankshaft Install a 3 8 breaker bar into the slot of the holding tool so it is perpendicular to both the holding tool and crankshaft or insert a shoulder bolt through the slot and thread it into the mounting hole If the flywheel end is more accessible you can use a breaker bar and socket on the flywheel nut screw to hold it in position You may need an assistant to hold the breaker bar during testing If the engine is mounted in a piece of equipment you may be able to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester at this time 5 Connect an adequate air source 80 100 psi to the tester 6 Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low right end of the scale 7 Connect the tester quick disconnect to the adapter Note the gauge reading and listen for escaping air at the carburetor inlet exhaust outlet and or crankcase breather 8 Check your test results against the table below Leakdown Test Results Air escaping from crankcase breather ssseessseeeenreeeenn Air escaping from exhaust system
69. e throttle control does not have a designated choke on position be sure to leave sufficient throttle control travel past the fast position This will enable the choke to be placed on See Figure 5 14 Cold Engine Warm Engine Figure 5 14 Typical Throttle Choke Controls 3 Align the hole in the throttle lever with the hole in the speed control bracket by inserting a pencil or 6 35 mm 1 4 in drill bit See Figure 5 15 5 10 pencil or Drill Bit Figure 5 15 Aligning Holes in Speed Control Bracket and Throttle Lever 4 Pull onthe outer shield of the throttle control cable to remove any slack Tighten the cable clamp securely Starting an Engine Equipped with Unitized Throttle and Choke Control 1 Fora Cold or Warm Engine Place the throttle choke control into the fast choke on position This will also place the choke into the on position See Figure 5 16 Figure 5 16 Throttle Position for Starting Engine 2 Make sure the equipment is in neutral 3 Activate the starter switch Release the switch as soon as the engine starts www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE If the engine dev
70. e to Remove Governor Shaft 1 Remove the blower housing flywheel and cooling fan 2 Remove the stator and crankshaft key 3 Remove the closure plate screws and closure plate 4 Rotate engine to top dead center aligning timing marks on the crankshaft and cam gears 5 Remove the governor gear assembly and regulating pin from the closure plate with two small screwdrivers 6 Locate the governor pin from flywheel side With a small punch drive the pin out of the closure plate This could also be done with a press DO NOT remove the governor pin with a vise grip or pliers you may damage the closure plate 7 Remove any old gasket material from the mating surfaces of the crankcase and closure plate Use an aerosol gasket remover to help loosen any old gasket material Do not scrape the surfaces as any scratches nicks or burrs can result in leaks Procedure to Install Governor Shaft 1 Install new pin by pressing or lightly tapping it into the closure plate It must be installed so that it protrudes 44 50 mm 1 750 in plus or minus 0 101 mm 0 004 in above the crankcase boss See Figure 9 16 Governor Gear 44 50 mm 1 750 in To Gasket Surface Before Oil Passage Cover Plate and Gasket are Assembled Figure 9 16 Governor Shaft Press Depth 2 Install the new governor regulating pin and governor gear assembly www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Sec
71. e wiring 2 If voltage is 13 volts or more stator is OK harness Check for loose connections or shorts in wiring harness With engine running at in the fast setting No measure voltage from lighting lead to If voltage is less than 13 volts test stator Lights ground using an AC voltmeter using an ohmmeter Test 3 3 With engine stopped measure the 3 If resistance is approximately 0 2 ohms resistance of stator from lighting lead to stator is OK ground using an ohmmeter If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 7 8 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Troubleshooting Guide 3 amp 70 Watt Braking Stator NOTE Zero ohmmeteres on each scale to ensure accurate readings Voltage tests should be made with engine running at full throttle no load Battery must be fully charged 1 With engine running in the fast setting measure voltage across battery terminals using a DC voltmeter the wiring harness With engine running in the fast setting measure voltage from charging lead to ground using a DC voltmeter With charging lead disconnected from battery and engine stopped measure resistance from charging lead to ground using an ohmmeter Note reading Battery again reversed some resistance should be Disconne
72. echanical governor designed to hold the engine speed constant under changing load conditions The governor gear flyweight mechanism is mounted on the closure plate in the crankcase and is driven off a gear on the crankshaft See Figure 5 20 es Figure 5 20 Governor Gear Flyweight Assembly fe 5 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Operation As the governor gear rotates centrifugal force causes the flyweights to move outward as speed increases As the flyweights move outward they cause the regulating pin to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate One end of the cross shaft protrudes through the side of the crankcase The governor lever is clamped on the protruding end of the shaft and connected with linkage to the throttle lever on the carburetor so any rotation of the shaft causes corresponding movement of the throttle plate When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating the force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin are in equilibrium during operation holding the engine speed c
73. eck pressure Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guides Repair replace restricted muffler exhaust system 3 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 3 Troubleshooting Compression Test These engines are equipped with an automatic compression release ACR mechanism Because of the ACR mechanism it is difficult to obtain an accurate compression reading As an alternate use the leakdown test described below Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly SPX Part No KO3219 previously Kohler Part No 25 761 05 S is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect coupling for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug 3 Rotate the crankshaft until the piston is at top dead center of the compression stroke You will need to hold the engine in this position while testing The holding tool supplied with the tester can be used if th
74. eeeesaeeees 5 5 N m 50 in Ib Electric Starter TOI BOR TOPIC E 3 3 3 9 N m 30 35 in Ib Mounting Nut el e 3 6 N m 82 in Ib Nut Top Positive Brush Lead Terminal REENEN EEN 1 6 2 8 N m 15 25 in Ib Nut Flange Positive Brush Lead Terminal ssesnssesennnsnsennneessnnnnen 2 2 4 5 N m 20 40 in Ib Fan Flywheel Flywheel Retaining Screw Torque nnno0nnnnnnennnnosannnnosnnnnnennnnnnnnnnnnnnn 66 5 N m 588 in Ib Governor Governor Cross Shaft to Crankcase Running Clearance saeessseaeaa 0 013 0 075 mm 0 0005 0 003 in Governor Cross Shaft O D KI 5 975 6 012 mm 0 2352 0 2367 in Max Wear Bu EE 5 962 mm 0 2347 in Governor Gear Shaft to Governor Gear Running Clearance 00000 0 09 0 16 mm 0 0035 0 0063 in Governor Gear Shaft O D KI 5 99 6 00 mm 0 2358 0 2362 in Max Wear un 5 977 mm 0 02353 in Ignition Spark Plug Type Champion or Equivalent 0ccccccsseeeceeeeeeeeeeeeaeeees RC12YC or QC12YC DPRP UT E 0 76 mm 0 030 in ear Plug Tee TEE 24 30 N m 18 22 ft Ib Ignition Module Air Gap a ccccsdaste sce saan dco deancededaceesseceustaaiouscantisesycosdenaeccocess 0 203 0 305 mm 0 008 0 012 in Ignition Module Fastener Torque n0nnnnannnannnnannnnnnnnnnnennnnnnnonrrnnrenennnne 6 0 N m 55 in Ib Into new as cast hole 4 0 N m 85 in Ib Into used hole Muffler Muffler Retaining Nuts Torque A 24 4 N m 216 in Ib Oil Filter O regele TEE 10
75. eeessaeseessneees obtain locally Waler e Le EE KO1048 VACUUM GAUGE ccccseeeccceeseeseceeeeeeseceeeaeeeeeeeaaeceeeesseeeeesseaeeeeeseaeeeeesseaeseeeeaas KO3223 Cylinder Leakdown Tester E KO3219 Ignition System Tester gensstaccinaereetreconaes once meantcactastutcensattennpasainerneatencenaedscoepeqsane KO1046 AD WG FSI EE KO3218 Inductance Tachometer ccccceeeeccseeeccceeeecceueeeceeeccesaeeeeseueeeeseaeeessaeseessaneees KO3216 Some of the specialty tools are shown and mentioned at various points in this manual A complete catalog of all available tools may be ordered under Kohler Part No TP 2546 The tool price list is available under Kohler Part No TP 2547 Special Tools You Can Make Flywheel Holding Tool Flywheel removal and reinstallation becomes a snap using a handy holding tool you can make out of a piece of an old junk flywheel ring gear as shown in Figure 2 2 Using an abrasive cut off saw cut out a six tooth segment of the ring gear as shown Grind off any burrs or sharp edges The segment can be used in place of a strap wrench Invert the segment and place it between the ignition module bosses on the crankcase so the tool teeth engage the ring gear teeth on the flywheel The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 1 Tool Catalog and Price List 2 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678
76. eflector is made from a plastic that is quite brittle Do not pry on the corners or you risk cracking breaking the deflector If prying is necessary to loosen the deflector carefully pry near the intake stud only See Figure 8 19 Remove the mounting stud from the cylinder only if required Figure 8 16 Removing Speed Control Bracket from Closure Plate Figure 8 17 Disconnecting Governor Spring 6 Loosen the hex flange nut and remove the governor lever from the governor cross shaft See Figure 8 18 NOTE It is recommended that a new governor lever be installed whenever removal is performed 8 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Remove Ignition Module 1 Disconnect the kill lead from the ignition module 2 Rotate the flywheel magnet away from the module 3 Remove the RFI sheathed spark plug lead with from retaining clip if so equipped See Figure 8 20 Figure 8 20 Removing Lead from Clip RFI Suppression Equipped Units 4 Remove the two hex flange screws and the ignition module See Figure 8 21 Figure 8 21 Removing Ignition Module Remove Grass Screen Fan and Flywheel 1 Unsnap the grass screen from the cooling fan See Figure 8 22 8 6 BW Figure 8 22 Removing Grass Screen NOTE Always use a flywheel strap wrench or flywheel holding tool see Section 2 to hold the flywheel when loosening or tig
77. elops sufficient speed to disengage the starter but does not keep running a false start engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter If the starter does not turn the engine over shut the starter off immediately Do not make further attempts to start the engine until the condition is corrected Do not jump start using another battery refer to Battery See your Kohler Engine Service Dealer for trouble analysis 3 For Operation After the engine starts move the throttle choke control from the fast choke on position and set the desired engine operating speed between the slow and fast position High Speed RPM Adjustment The recommended maximum no load high speed RPM for most engines is 3300 RPM The actual high speed RPM depends on the application Refer to the equipment manufacturer s instructions for specific information A WARNING Over speed is Hazardous Do not tamper with the governor setting Over speed is hazardous and could cause personal injury 1 Make sure the throttle cable is adjusted properly see Throttle Cable Adjustment 2 Start the engine and allow it to warm up Place the throttle control lever into the fast or high speed position Turn the choke adjustment scr
78. emoving the Oil Sentry pressure switch or pipe plug and threading the tester hose directly into the mounting hole See Figure 6 10 Locations For Tester 7 Figure 6 10 Tester Locations www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 7 Electrical System and Components This section covers the operation service and repair of the electrical system and electrical system components Major electrical systems and components covered in this section include the ignition system battery battery charging systems electric starter and optional Oil Sentry oil level pressure switch A WARNING Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Spark Plug NOTE Do not clean the spark plug in a machine Engine misfire or starting problems are often caused using abrasive grit Some grit could by a spark plug that is in poor condition or has an remain in the spark plug and enter the improper gap setting engine causing extensive wear and damage The engine is equipped with the following spark plug 3 Check the gap using a wire feeler gauge Adjust Type Champion RC12YC or QC12YC the gap by carefully bending the ground electrode Gap 0 76 mm 0 030 in Gap plugs to 0 76 mm 0 030 in See Figure 7 1 Thread Size 14mm 7 Reach 19 1 mm 3 4 in Wire Gauge Hex Size 15 9 mm 5 8 in
79. er Remove Air Cleaner 1 Loosen the two knobs and remove the air cleaner cover See Figure 8 7 Figure 8 7 Removing Air Cleaner Cover 2 Remove the precleaner if so equipped and the air cleaner element with the formed rubber seal See Figure 8 8 Figure 8 8 Air Cleaner Components Section 8 Disassembly 3 Remove the two hex flange nuts or single nut and long mounting screw securing the air cleaner base See Figure 8 9 Figure 8 9 Removing Air Cleaner Base Fasteners 4 Disconnect the breather hose from the valve cover and remove the air cleaner base and gasket See Figure 8 10 Figure 8 10 Removing Air Cleaner Base and Breather Hose Remove External Governor Components Carburetor and Fuel Pump A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 8 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly 1 Shut off the fuel supply Disconnect the fuel line from the carburetor inlet fitting See Figure 8 11 If a fuel pump is used disco
80. ere removed 7 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Retaining Ring Installation 1 Position the retaining ring in the groove in one of the inner halves Assemble the other half over the top and slide on the outer collar Be certain the drive components are installed in correct sequence onto the armature shaft Slip the tool over the end of the armature shaft so the retaining ring inside is resting on the end of the shaft Hold the tool with one hand exerting slight pressure toward the starter Tap the top of the tool with a hammer until you feel the retaining ring snap into the groove Disassemble and remove the tool Squeeze the retaining ring with pliers to compress it into the groove Assemble the inner halves with the larger cavity around the spring retainer see Figure 7 15 Slide the collar over them and thread the center screw in until resistance Is felt Figure 7 15 Assembling Larger Inner Half Around Spring Retainer 6 Hold the base of the tool with a 1 1 8 wrench and turn the center screw clockwise with a 1 2 or 13 mm wrench to draw the spring retainer up around the retaining ring Stop turning when the resistance increases Disassemble and remove the tool Starter Disassembly 1 2 Remove the hex flange nut and insulating washer 7 16 Remove the drive components following the inst
81. etaining knobs and remove the air cleaner cover 2 Remove the foam precleaner if so equipped and the air cleaner element with formed rubber seal 3 Disconnect the breather hose from the valve cover or air cleaner base NOTE The air cleaner base should be removed only if necessary 4 Remove the two hex flange nuts from the mounting studs If one stud and one thread forming screw is used first remove the thread forming screw on the right side of the carburetor inlet which secures the air cleaner base carburetor and gaskets Insert a 3 16 diameter rod approximately 4 long into the hole to serve as a temporary alignment pin Be careful not to force the rod or damage the threads Then remove the hex flange nut from the stud on the left side of the carburetor inlet Carefully remove the air cleaner base and gasket The cover mounting studs thread into the air cleaner base and they should only be removed if necessary Section 4 Air Cleaner and Air Intake System Reassembly The following procedure is for complete assembly of all air cleaner components Steps 1 3 are necessary only if the air cleaner base and or the cover mounting studs were removed in Disassembly 1 Install the mounting studs into the air cleaner base if removed previously Tighten the studs until bottomed or to the end of threads do not force Install the air cleaner base gasket and air cleaner base with the two metal spacers o
82. ew See Figure 5 13 out conterclockwise so there is clearance from the choke lever and that contact cannot occur during Step 4 See Figure 5 13 3 Align the hole in the throttle lever with the hole in the speed control bracket by inserting a pencil or 6 35 mm 1 4 in drill bit See Figure 5 15 Section 5 Fuel System and Governor 4 Loosen the speed control bracket mounting screws Slide the bracket forward or backward until the desired high speed RPM is reached See Figure 5 17 Check the speed with a tachometer Figure 5 17 Adjusting High Speed RPM To increase the high speed RPM move the bracket toward the carburetor To decrease the high speed RPM move the bracket away from the carburetor Tighten the speed control bracket mounting screws Recheck the speed with a tachometer and readjust if necessary Torque the mounting screws as follows Into new as cast hole 11 0 N m 95 in Ib Into used hole 7 5 N m 65 in Ib Adjust the choke see Choke Adjustment which follows Choke Adjustment This procedure must follow the High Speed Adjustment just described If not already completed perform that operation first 1 Turn the choke adjusting screw out counterclockwise until it no longer contacts the choke lever Then turn it back in clockwise until it just makes contact 5 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 49
83. ff valve closed Dirt or water in the fuel system Clogged fuel line Spark plug lead disconnected Key switch or kill switch in off position Faulty spark plug Faulty ignition module Inoperative fuel solenoid Choke not closing See eae eS zech Engine Starts But Does Not Keep Running 1 Vent in fuel cap restricted 2 Dirt or water in the fuel system 3 Faulty choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground Faulty carburetor Faulty cylinder head gasket D o Engine Starts Hard PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty choke or throttle controls Faulty spark plug Low compression Faulty ACR mechanism oe ele ee en Engine Will Not Crank or St ge e PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter Seized internal engine components Engine Runs But Misses 1 5 6 Dirt or water in the fuel system 2 Spark plug faulty or fouled Se 4 Spark plug lead boot loose on plug Loose wires or connections that intermittently short the kill terminal of ignition module to ground Engine overheated Faulty ignition module or improperly gapped Engine Will Not Idle ae oe oN Vent in fuel cap restricted
84. he engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Identification Decal Figure 1 1 Engine Identification Decal Location A Model No SV 540 S Courage Vertical Shaft Engine T Ter sion Code S Electric Start Numerical Designation MODEL NO SPEC NO SERIAL NO Spec No SV540 0001 REFER TO OWNER S MANUAL FOR Engine Model First spec SAFETY MAINTENANCE SPECS oe AND ADJUSTMENTS FOR SALES Model written in this AND SERVICE IN US CANADA SV470 model series CALL 1 800 544 2444 SV480 www kohlerengines com SV530 SV540 KOHLER 1 ISS SV590 KOHLER CO KOHLER WI USA SV600 Serial No 3205810334 TE Year Manufactured Code Factory Code Code Year 32 2002 33 2003 34 2004 Figure 1 2 Explanation of Engine Identification Numbers 1 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase Is extremely important as is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown below RECOMMENDED SAE VISCOSITY GRADES 5W 20 5W 30
85. hrough the precleaner if SO equipped the paper element and then into the carburetor The outer air cleaner cover is secured by two knobs and removed by turning the knobs counterclockwise Air Cleaner Element Air Cleaner Cover Air Cleaner Cover Knobs Precleaner Service If so equipped wash and oil the precleaner every two months or every 25 hours of operation more often under extremely dusty or dirty conditions 1 Loosen the air cleaner cover knobs and remove the cover 2 Remove the precleaner 4 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 4 Air Cleaner and Air Intake System 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner into the outer cover 6 Install the air cleaner cover and secure with the two knobs 7 When precleaner replacement is necessary order Kohler Part No 20 083 01 S Paper Element Service Check the paper element every two months or every 25 hours of operation more often under extremely dusty or dirty conditions Clean or replace the element as necessary Replace the air cleaner element annually or every 100 hours 1 Remove the air cleaner cover and the precleaner
86. htening the flywheel and fan retaining fasteners Do not use any type of bar or wedge between the fins of the cooling fan as the fins could become cracked or damaged 2 Remove the retaining screw washer and the fan mounting plate securing the fan and flywheel to the crankshaft See Figure 8 23 Figure 8 23 Removing Fan and Flywheel Mounting Hardware 3 Carefully lift the cooling fan to disengage the two drive pins and remove it from the flywheel 4 Remove the flywheel from the crankshaft using a puller See Figure 8 24 NOTE Always use a puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as they could be cracked or damaged www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly Figure 8 24 Removing Flywheel Using Puller Figure 8 26 Removing Valve Cover Screws 5 Remove the flywheel key from the crankshaft 2 Remove the valve cover and gasket from the cylinder head See Figure 8 27 Remove the Stator 1 Remove the two screws securing the stator to the closure plate bosses See Figure 8 25 NOTE To disconnect the B or stator leads from the wiring harness connector insert a small screwdriver or similar narrow flat blade and bend down the locking tang of the terminal s Gently pull the lead s out of the connector Figure 8 27 Valve Cover and Gasket Details 3 Loosen the inner set screws T15 TORX a
87. if so equipped service as required 2 Remove the air cleaner element with the integral rubber seal 3 Gently tap the pleated side of the paper element to dislodge dirt Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the rubber seal is damaged 4 Clean all air cleaner components of any accumulated dirt or foreign material Prevent any dirt from entering the throat of the carburetor 5 Install the air cleaner element with the pleated side out and seat the rubber seal onto the edges of the air cleaner base 6 Reinstall the precleaner if so equipped into the upper section of the air cleaner cover Make sure the hole in the precleaner is aligned with the upper mounting knob See Figure 9 7 Reinstall the air cleaner cover and secure with the two knobs 4 2 8 When element replacement is necessary order Kohler Part No 20 083 02 S Inspect Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or precleaner is serviced check the following areas components Outer Air Cleaner Cover Make sure the air cleaner cover is in good condition not cracked damaged or missing a retaining knob which can affect the sealing ability of the air cleaner element Air Cleaner Base Make sure the base is properly secured and not cracked
88. ilable in STD and 0 08 mm 0 003 in oversize which include new rings and piston pins Service replacement piston ring sets are also available separately Always use new piston rings when installing pistons Never reuse old rings The cylinder bore must be deglazed before service ring sets are used y ge em t a 5 itt f 2E A P i f t 1 ea IEAA E BS S ain IA TT l ie nu eko OK STM Fe e R DS ale Wy Say Scored Piston and Rings Figure 9 12 Common Types of Piston and Ring Damage 9 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning Some important points to remember when servicing piston rings 1 Ifthe cylinder bore is within the wear limits refer to Section 1 and the old piston is within wear limits free of score or scuff marks the old piston may be reused 2 Remove old rings and clean up grooves Never reuse old rings 3 Before installing the rings on the piston place each of the top two rings in its running area in the cylinder bore and check the end gap see Figure 9 13 Compare to the listed specifications Figure 9 14 Measuring Piston Ring Side Clearance Top and Middle Compression Ring End Gap New Bore Install Piston Rings Top Bing 0 15 0 40 mm 0 006 0 016 in To install piston rings proceed as follows Middle Ring 0 30 0 55 mm 0 012 0 022 in Max Used Bore
89. ing Alignment Pin 5 Install a new carburetor gasket onto the mounting stud s and or alignment pin 10 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly 6 Attach the choke and throttle linkages to the carburetor and install the carburetor assembly See Figure 10 55 If the governor lever was not disconnected slide it onto the governor shaft with the lever up Throttle Linkage Figure 10 57 Fuel Solenoid Lead Secured with Tie Strap 8 Connect the fuel line to the carburetor and secure with a hose clamp See Figure 10 58 Figure 10 55 Installing Carburetor Assembly with Linkages 7 Ifthe carburetor has a fuel solenoid fasten the ground lead to the crankcase boss with the toothed washer between the eyelet terminal and the boss See Figure 10 56 Torque the screw to 8 0 N m 70 in Ib Connect the solenoid power lead to the wiring harness and secure with a tie strap See Figure 10 57 Figure 10 58 Connecting Fuel Line to Carburetor 9 Install the air cleaner base a Install a new air cleaner base gasket Check that the two metal spacers are in the air cleaner base mounting holes and install the base onto the stud s and or alignment pin Make sure the upper mounting tab is positioned above the closure plate boss See Figure 10 59 Install the hex flange nut s Figure 10 56 Securing Ground Lead and finger tighten See Figure 10 60
90. ing on the equipment powered by the engine 3 Prevent the stator leads from touching or shorting while the engine is running This could damage the stator www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Lighting Lead Yellow Charging Lead Black Figure 7 7 3 Amp 70 Watt Stator Optional Oil Sentry Switch Indicator Light d Ss Ground To gd i 8 Kill Lead Ignition Module A oj C ACI Regulator Rectifier Violet Optional Oil Sentry Recommended Bi Fuse Rating Optional Fuel 25 30 AMP Connector solenoid Optional Oil Starter Sentry Switch Solenoid WW Shutdown or L Indicator Battery Bendix Starter Figure 7 8 3 amp Unregulated Battery Charging System 70 Watt Lighting V0 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE Zero ohmmeteres on each scale to ensure accurate readings Voltage tests should be made with engine running at full throttle no load Battery must be fully charged Conclusion 1 With engine running in the fast setting 1 If voltage is more than 12 5 volts charging measure voltage across battery terminals system is OK using a DC voltmeter If voltage is 12 5 volts or less the
91. ion Moisture in fuel or from deposits seen here indicate very high combustion condensation are the most common causes of valve temperatures usually due to a lean fuel mixture stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Gum Gum deposits usually result from using stale Overheating An exhaust valve subject to overheating gasoline This condition is often noted in applications will have a dark discoloration in the area above the where fuel is not drained out of tank during the off valve guide Worn guides and faulty valve springs may season Gum is a prevalent cause of valve sticking cause this condition Also check for clogged air intake The cure is to ream the valve guides and clean or and blocked fins when this condition is noted replace the valves depending on their condition 9 8 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burned valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter Then using an outside micrometer measure the diameter of the
92. ioning the oil ring rails may spring out and jam between the ring compressor and the top of the bore Install Piston to Connecting Rod 1 Assemble the piston connecting rod piston pin and piston pin retainers See Figure 10 16 10 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Install Cam Levers 1 Install the two cam levers as shown in Figure 10 20 The dimple for seating the push rod must face up Secure each cam lever using an M6 hex flange screw Torque the screws to 7 5 N m 65 in Ib Lubricate the dimple and bottom side of the cam lever with light grease or oil Figure 10 20 Installing Cam Levers Install the Exhaust Cam Shaft and Cam Gear 1 Ifthe drive pins were removed from the exhaust cam shaft follow the same procedure used earlier Figure 10 18 Installing Piston and Connecting for the intake cam shaft and reinstall them See Rod Figure 10 21 3 Guide the connecting rod down and rotate the crankshaft to mate the journals Install the rod cap 4 Install the hex flange screws and torque in 2 increments first to 5 5 N m 50 in Ib finally to ES E E BE FE 11 5 N m 100 in Ib See Figure 10 19 eT Bee Ee se LLLL LLL LLL LLL LL A P LLLLL MEE ED LLL WA Figure 10 21 Drive Pin Locations for Exhaust Cam Shaft 1 2 3 4 g 6 Exhaust Cam Shaft 3 mm Diameter Pin 2 5 mm Diameter Pin 1 86 m
93. k the long leg behind the notchedtab See Figure 10 24 Figure 10 25 Installing Exhaust Cam Gear 10 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Install Intake Cam on Cam Shaft 1 Lift the intake cam lever and install the intake cam gear onto the intake cam shaft engaging the slot with the upper drive pin Rotate the gear and shaft so the IN timing mark on the cam gear is in the 4 o clock position Install the thrust washer onto the cam shaft See Figure 10 26 Figure 10 26 Installing Intake Cam Gear and Thrust Washer Install Crank Gear 1 Orient the crankshaft so the key is in the 12 o clock position Hold the crank gear with the timing marks visible and slide it onto the crankshaft and key so the timing marks on the crank gear align with the timing marks on the cam gears See Figure 10 27 Figure 10 27 Installing Crank Gear 10 8 Install Flywheel Side Oil Seal 1 Lubricate the outside diameter and lip of the flywheel end oil seal Support the closure plate and install the oil seal Using a seal driver drive the seal to a depth of 5 mm 0 196 in in the seal bore See Figure 10 28 Install Closure Plate Gasket Closure Plate and Wiring Harness NOTE The special gasket used between the closure plate and crankcase controls crankshaft endplay no shimming is required Do not use RTV sealant in place of the gasket 1 Ma
94. ke sure the sealing surfaces of crankcase and closure plate are clean dry and free of any nicks or burrs Install a new closure plate gasket onto the crankcase Important 2 Apply grease to the outside flat surfaces of the balance weight guide shoe Position the guide shoe so the solid end is toward the crankshaft See Figure 10 29 Make sure the guide shoe stays in this position during the next step 3 Ensure the gasket cover plate and governor gear assembly have been properly assembled to the closure plate refer to Section 9 Start the closure plate onto the crankcase Be sure the guide shoe is aligned with the guide channel in the closure plate and the cam shafts and governor gear shaft are aligned with their mating bearing surfaces See Figure 10 29 As the plate is lowered into final position rotate the crankshaft slightly if necessary to help engage the governor gear www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Guide Channel Figure 10 29 Aligning and Installing Closure Plate 4 Install the fourteen hex flange screws securing Figure 10 31 Closure Plate Fastener Torque the closure plate to the crankcase with any Sequence clamps for the wiring harness and the sheathed RFI suppression spark plug lead 5 location if Assemble Cylinder Head so equipped positioned as shown in Figure Prior to assembly lubricate all the components with
95. l quickly Drain Oil from Crankcase and Remove Oil remove grease oil and grime from engine parts Filter ER EE e DEE 1 Remove the oil drain plug and oil fill cap dipstick manufacturer s instructions and safety precautions See Figure 8 1 carefully l 2 Allow ample time for the oil to drain from the Make sure all traces of the cleaner are removed crankcase before the engine is reassembled and placed into operation Even small amounts of these cleaners can 3 quickly break down the lubricating properties of l engine oil Remove and discard the oil filter Typical Disassembly Sequence Drain oil from the crankcase and remove oil filter Remove blower housing Disconnect spark plug lead Remove muffler Remove rectifier regulator Remove electric starter Remove air cleaner Remove external governor components carburetor and fuel pump 9 Remove ignition module 10 Remove grass screen fan and flywheel 11 Remove stator Figure 8 1 Oil Drain Location Oil Filter and Oil 12 Remove valve cover and cylinder head Fill Cap Dipstick 13 Remove closure plate and wiring harness 14 Remove cam gears cam shafts and oil pump 15 Remove connecting rod and piston 16 Remove piston from connecting rod 17 Remove piston rings ooo NS 8 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 section 8 Disassembly Remove Oil Sentry Pressure Switch Remove Muffler on
96. lace burned out lights 2 If voltage is 13 volts or more stator is OK Check for loose connections or shorts in wiring harness If voltage is less than 13 volts test stator using an ohmmeter Test 3 If resistance is approximately 0 15 ohms stator is OK 3 If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 7 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Troubleshooting Guide 3 amp 70 Watt Braking Stator cont 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the braking lead green from 2 If voltage is 35 volts or more stator is the wiring harness OK Circuitry on unit that grounds braking No lead is shorted Lights With engine running in the fast setting Or measure voltage from braking lead to If voltage is less than 35 volts test Battery ground using an AC voltmeter stator using an ohmmeter Test 3 Charging With the engine stopped measure the lf resistance is approximately Braking resistance from braking lead to ground 0 2 0 4 ohms stator is OK System using an ohmmeter Test If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 7 10 www mymowerparts com Kohler Engine Parts Call K amp T
97. lage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Periodic Maintenance A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnec
98. ling fan See Figure 10 69 Installing Rectifier Regulator Figure 10 72 Install Blower Housing and Flywheel Screen 1 Position the blower housing on the engine and route the spark plug lead through the underside slot See Figure 10 70 10 19 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Figure 10 72 Installing Grass Screen Install Oil Sentry or Pipe Plug 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the 1 8 pipe plug or adapter Install and tighten into the port on the closure plate See Figure 10 73 Torque pipe plug to 4 5 5 0 N m 40 45 in Ib If a switch was installed apply sealant to the threads of the Oil Sentry switch and install into the adapter or center passage Torque the switch to 4 5 5 0 N m 40 45 in Ib Connect the green wiring harness lead to the terminal on the switch See Figure 10 74 Center Passage Figure 10 73 Installing Pipe Plug or Adapter 10 20 Oil Sentry Switch Figure 10 74 Installed Oil Sentry Switch Install Air Cleaner Element Precleaner and Air Cleaner Cover 1 Install the air cleaner element with the pleated side out Seat the rubber seal onto all the edges of the air cleaner base See Figure 10 75 Da H am amp axe el aw e Figure 10 75 Installing Air Cleaner Element ge KS 8 x 2 Install the precleane
99. ll the battery Poor performance or early failure due to loss of electrolyte will result 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid or grime on the external surfaces can self discharge the battery Self discharging happens rapidly when moisture is present 3 Wash the cables terminals and external surfaces with a baking soda and water solution Rinse thoroughly with clear water 7 6 NOTE Do not allow the baking soda solution to enter the cells of the battery as this will desiroy the electrolyte Battery Test Test the battery voltage by connecting a DC voltmeter across the battery terminals and cranking the engine If the battery drops below 9 volts while cranking the battery is discharged or faulty Refer to Figure 7 6 Battery Figure 7 6 Checking Battery Voltage Electrical Systems Wiring Diagrams and Battery Charging Systems Most engines are equipped with either a 9 or 15 amp regulated battery charging system Some have a3 amp unregulated system with a 70 watt lighting circuit Refer to the following wiring diagrams and troubleshooting guides to test and service the system NOTE Observe the following guidelines to prevent damage to the electrical system and components 1 Make sure the battery polarity is correct A negative ground system is used 2 Disconnect the battery cables negative cable first before doing electric weld
100. m 1 Hole Location 2 Hole Location Figure 10 19 Torquing Connecting Rod Fasteners 10 6 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly 2 Apply a dab of grease to the formed groove in the thrust washer Slide the washer onto the cam shaft so the short drive pin is seated in the groove The grease will hold the washer in position Pivot the exhaust cam lever toward the push rod bore then insert the cam shaft into the counterbore of the crankcase Make sure the pin stays in the groove of the thrust washer See Figure 10 22 CN Figure 10 24 Hooking ACR Spring onto Exhaust Cam Gear Exhaust Lever 5 Lift the exhaust cam lever and install the exhaust cam gear with assembled ACR onto the cam shaft engaging the slot with the upper drive pin Rotate the gear and shaft so the EX timing mark Figure 10 22 Exhaust Cam Shaft Installation on the cam gear is in the 8 o clock position Install the thrust washer onto the cam shaft See Figure 3 Lubricate the cam surfaces of the cam gears with 10 25 light grease or oil 4 Assemble and install the ACR automatic compression release into the exhaust cam gear if removed for servicing a Install the spring onto the ACR weight with loop around post and the formed upper leg hooked behind the upper section See Figure 10 23 b Install the ACR assembly into hole of exhaust cam gear and hoo
101. m 45 55 in Ib Fuel Shut off Solenoid Many engines are equipped with a fuel shut off solenoid installed in place of the bowl retaining screw to eliminate backfiring when the engine is shut down If backfiring occurs on engines equipped with this solenoid verify that the correct shutdown procedure is being used In order for the solenoid to be effective the engine must be running between half and full throttle when the key is turned off Next check the battery to ensure that it is not discharged or faulty A minimum of 7 3 volts DC is required to activate the solenoid Also check to see that the ground lead from the carburetor body to the air cleaner base mounting screw is properly connected If these check out the solenoid should be removed for bench testing Remember to shut off the fuel supply and catch any fuel spilling from the carburetor as the solenoid is removed Bench test the solenoid by grounding the solenoid case and applying 12 volt DC to the spade terminal If the plunger does not retract the solenoid is faulty and must be replaced Always use a new fuel bowl gasket whenever the solenoid is installed Refer to the wiring diagram in Section 7 and connect the fuel shut off solenoid Section 5 Fuel System and Governor Figure 5 11 Fuel Shut Off Solenoid High Altitude Operation When operating the engine at altitudes of 1830 m 6000 ft and above the main fuel mixture tends to get over rich An over rich
102. miter cap on the idle fuel adjustment needle Step 2 can only be performed within the limits allowed by the cap 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing steps 2 and 3 2 Low idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the low idle fuel adjustment needle out counterclockwise from the preliminary setting until engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Set the adjusting needle midway between the rich and lean settings See Figure 5 4 Adjust to Midpoint vt Figure 5 4 Optimum Low Idle Fuel Setting NOTE If the engine is equipped with a governed idle adjustment See Figure 5 19 the governor will compensate for soeed changes due to the low idle mixture adjustment Disable the governed idle control by backing out the governed idle adjusting screw and setting a fixed idle speed using the idle soeed screw on the carburetor Make the low idle mixture adjustment and then reset the governed idle speed at the adjusting screw Section 5 Fuel System and Governor Low Idle Speed Setting 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing step 2 L
103. mixture is then burned in the engine combustion chamber Troubleshooting Use the following procedure to check if fuel is reaching the combustion chamber 5 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Fuel System Troubleshooting Guide Test Conclusion 1 Check for the following a Make sure the fuel tank contains clean fresh proper fuel b Make sure the vent in fuel cap is open c Make sure the fuel valve is open 2 Check for fuel in the combustion chamber a Disconnect and ground spark plug lead b Close the choke on the carburetor c Crank the engine several times d Remove the spark plug and check for fuel at the tip 3 Check for fuel flow from the tank to the fuel pump a Remove the fuel line from the inlet fitting of the fuel pump b Hold the line below the bottom of the tank Open the shutoff valve if so equipped and observe flow 4 Check the operation of fuel pump a Remove the fuel line from the inlet fitting of the carburetor b Crank the engine several times and observe flow Fuel Filter Some engines are equipped with an in line fuel filter Periodically inspect the filter and replace when dirty Replacement is recommended annually or every 100 hours Use a genuine Kohler filter Fuel Pump Some engines are equipped with an optional pulse fuel pump See Figure 5 1 Operation The fuel pump has two inter
104. must be fully charged Trace B lead from rectifier regulator to key If voltage is 13 8 14 7 and charge rate switch or other accessible connection increases when load is applied the charging Disconnect it from switch or connection system is OK and battery was fully charged Connect an ammeter from loose end of B lead to positive terminal of battery Connect If voltage is less than 13 8 or charge rate does DC voltmeter from loose end of B lead to not increase when load is applied test stator negative terminal of battery See Figure 7 11 Tests 2 and 3 With engine running in the fast position read voltage on voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals No Remove connector from rectifier regulator If voltage is 28 volts or more stator is OK Charge With engine running in the fast position Rectifier regulator is probably faulty Verify with to measure AC voltage across stator leads using Rectifier regulator tester KO3221 Battery an AC voltmeter If voltage is less than 28 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 With engine stopped measure the resistance 3a If resistance is 0 1 0 2 ohms the stator is OK across stator leads using an ohmmeter
105. n and Reconditioning Valve Seat Cutter Figure 9 11 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide a good seal Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of engine oil to prevent rusting Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is part of the piston assembly if the pin boss or the pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with
106. n during cleaning Additionally the mating components crankshaft discard the dirty water and start again with more hot eccentrics and closure plate guide channel must also water and detergent Following the scrubbing rinse be inspected for wear or damage the cylinder with very hot clear water dry it completely and apply a light coating of engine oil to Use the following procedure to check the balance prevent rusting weight and matching components 9 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning Balance Weight to Eccentric Clearance Before the balance weight assembly is reassembled to the crankshaft the running clearance to the crankshaft eccentrics must be accurately checked Failure to maintain the required clearances will result in vibration or engine failure NOTE Do not use a feeler gauge to measure balance weight to eccentric clearance Measuring Balance Weight to Crankshaft Eccentric Ring s Clearance 1 Use an inside micrometer telescoping gauge or bore gauge and measure the inside diameter of the balance weight bearing surface Take two measurements 90 to each other on each weight See Figure 9 4 Figure 9 4 Measuring Balance Weight Bearing Surface 2 Then use an outside micrometer and measure across each eccentric on the crankshaft Again take two measurements 90 to each other See Figure 9 5 Figure 9 5 Measuring C
107. nal chambers separated by a diaphragm The air chamber is connected to the engine crankcase by a rubber hose The fuel chamber has an inlet from the fuel tank and an outlet to the carburetor The inlet and outlet each have an internal one way check valve Alternating negative and positive pressures in the crankcase activate the pump When the piston moves upward in the cylinder negative pressure vacuum is created in the crankcase and in the air chamber of the pump The diaphragm flexes toward the negative pressure and the suction draws fuel past the inlet check valve into the fuel chamber Downward movement of the piston causes a positive pressure in 5 2 If there is fuel at the tip of the spark plug fuel is reaching the combustion chamber lf there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 If fuel does flow from the line reconnect line and check for faulty fuel pump Test 4 If fuel does not flow from the line check for clogged fuel tank vent fuel pickup screen shutoff valve and fuel lines If fuel does flow from the line check for faulty carburetor Refer to the Carburetor portions of this section If fuel does not flow from the line check for clogged fuel line If the fuel line is unobstructed the fuel pump is faulty and must be replaced the crankcase and air chamber pushing the diaphragm in the opposite direction putting pressure on the fuel The i
108. nd back off the rocker arm adjusting nuts Remove the push rods and mark them so they can be reinstalled in the same location See Figure 8 28 Ce Ss i e em e Ee mmm Figure 8 25 Removing Stator Remove Valve Cover and Cylinder Head 1 Remove the seven screws securing the valve cover and any attached brackets See Figure 8 26 Soe ees ah ee am oy A KR GH De a lt S Kn SEN Figure 8 28 Lo Nut lt P amp we osening Adjustment Set Screw an d 8 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly 4 Remove the six hex flange screws securing the cylinder head Note the thick washer used on the screw closest to the exhaust port See Figure 8 29 a ast Figure 8 29 Removing Cylinder Head Bolts and Washer 5 Remove the cylinder head and head gasket See Figures 8 30 Figure 8 30 Removing Cylinder Head and Gasket 6 Remove the drain back check ball from the keyhole slot in the crankcase See Figure 8 31 8 8 oving Drain Back Check Ball RRATU H Figure 8 31 Rem from Crankcase Disassemble Cylinder Head NOTE Before disassembly mark all valve train components that will be reused to assure they are reassembled on the same side 1 Remove the spark plug See Figure 8 32 Figure 8 32 Removing Spark Plug 2 Remove the adjustment nuts pivots and rocker
109. nd hex flange nut onto the positive brush lead stud Make sure the stud is centered and does not touch the metal end cap Torque the hex flange nut to 2 2 4 5 N m 20 40 in Ib NOTE After installation and connection of the starter lead torque the outer nut to 1 6 2 8 N m 12 25 in Ib do not over torque Lubricate the drive shaft with Kohler bendix starter drive lubricant Part No 52 357 01 S Install the drive components following the instructions for servicing the drive The completed starter is shown in Figure 7 23 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 8 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead 2 Disconnect negative battery cable from battery The following sequence is suggested for complete 18 Remove crankshaft and balance weight engine disassembly This procedure can be varied to assembly accommodate options or special equipment 19 Remove balance weight assembly from crankshaft Clean all parts thoroughly as the engine is 20 Remove governor cross shaft disassembled Only clean parts can be accurately 21 Remove PTO and flywheel side oil seals inspected and gauged for wear or damage There are many commercially available cleaners that wil
110. ng needle and welch plugs Clean main fuel jet and all passages blow out with compressed air 4 Fuel leaks from carburetor Float level set too high See Remedy 2c Dirt under fuel inlet needle See Remedy 2d Bowl vent plugged Remove fuel bowl and clean bowl vent Blow out with compressed air Float is cracked or damaged Replace float Bowl retaining screw gasket damaged Replace gasket Bowl retaining screw loose Torque screw to specifications Carburetor Adjustment NOTE Carburetor adjustments should be made only after the engine has warmed up The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel jet is calibrated at the factory idle Fuel E 3 and is not adjustable The idle fuel adjustment needle y 4 ue 2 Mixture Needl z i p is also set at the factory and normally does not need adjustment If the engine is hard starting or does not operate properly however it may be necessary to adjust or service the carburetor NOTE Engines operating at altitudes above approximately 1830 m 6000 ft may require a special high altitude main jet Refer to High Altitude Operation later in this section Figure 5 3 Fixed Main Jet Carburetor 5 4 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Low Idle Mixture Adjustment NOTE Engines will have fixed idle no adjustment possible or a li
111. ng the oil pump and intake side cam shaft to the crankcase Carefully pull upward on the cam shaft to remove the assembly from the crankcase cavity A small rubber oil pump outlet seal on the outlet of the oil pump may become dislodged during removal Do not lose it See Figure 8 42 NOTE Most models use the outlet seal with the internal passage to feed oil to the lower main bearing Some models use a solid seal and the crankshaft is cross drilled to feed oil to the lower bearing If the seal needs to be replaced be sure the correct outlet seal is used Outlet Seal DN Figure 8 42 Intake Cam shaft and Oil Pump Assembly 5 If necessary the oil pump can be separated from the intake side cam shaft Providing appropriate support for the shaft drive out the lower pin The oil pump assembly can then be removed from the cam shaft See Figure 8 43 Section 8 Disassembly Jeng Figure 8 43 Separating Oil Pump Assembly from Intake Side Cam Shaft Remove Connecting Rod and Piston 1 Rotate the crankshaft so the rod journal is in the 9 o clock position 2 Remove the two hex flange screws and the connecting rod cap See Figures 8 44 NOTE Ifa carbon ridge is present at the top of the bore use a ridge reamer to remove it before attempting to remove the piston Figure 8 44 Removing Connecting Rod Cap 3 Carefully push the connecting rod and the piston away from the crankshaft and out of the cylinder
112. nlet check valve has now closed so the fuel is forced past the outlet check valve to the carburetor Repair Pulse fuel pumps are not serviceable and must be replaced when faulty Removal 1 Disconnect the inlet outlet and pulse lines from the fuel pump Mark the lines for proper reassembly 2 Remove the hex flange screws attaching the fuel pump Installation 1 Install the new fuel pump and secure with the hex flange screws Torque the hex flange screws to 5 9 N m 52 in Ib Do not over tighten 2 Connect the inlet outlet and pulse lines to their respective fittings on pump Secure with the clamps See Figure 5 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Troubleshooting Fuel System If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting or disassembling the carburetor e Make sure the fuel tank is filled with clean fresh gasoline e Make sure the fuel cap vent is not blocked and that it is operating properly e Make sure fuel is reaching the carburetor This includes checking the fuel shut off valve fuel tank filter screen in line fuel filter fuel lines and fuel pump as equipped for restrictions or faulty Figure 5 1 Pulse Fuel Pump components Carburetor P These engines are equipped with a Walbro fixed main Make sure the air cleaner base
113. nnect the pulse line from the fitting on the closure plate See Figure 8 12 Figure 8 13 Removing Heat Deflector Screw and Ground Lead 3 Ifthe carburetor uses a fuel solenoid carefully cut the plastic tie strap and disconnect the fuel _ solenoid lead from the wiring harness See Figure 8 11 Disconnecting Fuel Line from Figure 8 14 Carburetor s D GEN C Figure 8 14 Disconnecting Fuel Solenoid Lead Figure 8 12 Disconnecting Pulse Line from Fitting 4 Slide the carburetor outward and disconnect the throttle and choke linkages See Figure 8 15 2 Remove the heat deflector mounting screw and special washer which also secures the ground lead for the fuel shut off solenoid if so equipped See Figure 8 13 Figure 8 15 Removing Carburetor 8 4 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Disassembly 5 Mark the mounted position of the speed control bracket in the slotted holes and remove the two screws securing the speed control bracket to the closure plate Note or mark the governor spring hole for correct installation later Unhook the governor spring then remove the control bracket with fuel pump attached if equipped and linkages from the engine See Figures 8 16 and 8 17 Figure 8 18 Removing Governor Lever 7 Remove the carburetor gasket then carefully remove the heat deflector and gasket from the intake stud The heat d
114. nnennsenneeeerrenee 0 02 0 10 mm 0 001 0 004 in Carburetor Fuel Bowl Retaining Screw Torque ccccccecceeeeeeeeceaeseceeceaeeeeeseaaeseees 5 1 6 2 N m 45 55 in Ib Closure Plate Closure Plate Fastener Torque ccscccccececeseceeeeeaeeeeeeesaeeeeeeeesaeeeeeeeeas 24 5 N m 216 in lb Balance Weight Guide Channel Width EISE 17 95 18 05 mm 0 707 0 711 in Max Wear ELINA EE 18 13 mm 0 714 in Connecting Rod Cap Fastener Torque torque in 2 increments ccccseeeeeceseeeeseeeeeeeees 5 5 11 5 N m 50 100 in Ib Connecting Rod to Crankpin Running Clearance Kl 0 03 0 055 mm 0 0012 0 0022 in E WV et EE 0 07 mm 0 0025 in Connecting Rod to Crankpin Side Clearance cccccccsseeeeeeeseeeeaeeeeenees 0 25 0 59 mm 0 0098 0 0232 in Connecting Rod to Piston Pin Running Clearance ccccccccseeeeeeeeeeeeee 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D Kl 22 015 22 023 mm 0 8667 0 8670 in Wid VV Gal E ee E 22 036 mm 0 8675 in Crankcase Governor Cross Shaft Bore I D Kl 6 025 6 05 mm 0 2372 0 2382 in Max Wear E 6 063 mm 0 2387 in Oil Drain Plug Torque ceeccccccceseeceeceeeeeeeeeeeeeeeeeeeseaeeeeeesseeeeeeeaeaeeeeeeeas 14 0 N m 125 in Ib Crankshaft EAPO NOE ore a E E ene taiecceseenseeeere 0 225 1 025 mm 0 0089 0 040 in Crankshaft Bore in Crankcase I D Kl 41 965 41 990 mm 1 6521 1 65371 in EK e E opes T E E A R 42 016 mm 1 654 in Crankshaft Bore
115. nor Governor Sensitivity Adjustment The desired high speed setting RPM will determine Governor sensitivity is adjusted by repositioning the the governor spring position in the governor lever and governor spring in the holes in the governor lever If the throttle lever as well as the spring used See speed surging occurs with a change in load the Figure 5 23 governor is set too sensitive If a big drop in speed occurs when a normal load is applied the governor should be set for greater sensitivity Throttle Lever High Speed Governed Governor Throttle White Green RPM Idle RPM Lever Lever Spring Spring Hole No Hole No 3201 3400 2 2 x Hant n E Ooo S S T T Figure 5 23 Governor Spring Location Chart 5 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 6 Lubrication System Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES k i Kohler Command F 20 Q C 30 20
116. nt of oil to the outside diameter and lip of the PTO side oil seal before installing Use a seal driver and install to a depth of 5 5 mm 0 216 in into the crankcase See Figures 10 1 and 10 2 NOTE Always use new gaskets NOTE Make sure all components have been properly cleaned BEFORE reassembly Typical Reassembly Sequence 1 Install PTO side oil seal 2 Install governor cross shaft 3 Install oil pump and intake cam shaft assembly 4 Install crankshaft and balance weight 5 Install piston rings 6 Install piston to connecting rod 7 Install piston and rod to crankshaft 8 Install cam levers 9 Install exhaust cam shaft cam gear and ACR 10 Install intake cam gear V 11 Install oil seal into closure plate flywheel side 12 Install closure plate gasket closure plate and E wiring harness Figure 10 1 Installing PTO Side Oil Seal 13 Assemble cylinder head 14 Install cylinder head 15 Install rocker arms and push rods 16 Install valve cover 17 Install stator and wiring harness 18 Install flywheel and fan 19 Install electric starter 20 Install ignition module 21 Install spark plug 22 Install heat deflector carburetor linkage and air cleaner base 10 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly EE SRE AD BEEE OP BLES SIRT ES ST OE SEES ET SEE ST AI Ei l Oil Seal Seal Depth 5 5 mm 0 216 in
117. nto the mounting stud s and or alignment pin Make sure the upper mounting tab is located above the closure plate Install and finger tighten the hex flange nut s When a long M6 thread forming mounting screw is used apply hand pressure to keep the parts from shifting then remove the alignment pin and install the M6 thread forming screw DO NOT OIL Torque the nut s to 5 5 N m 48 in Ib Torque the screw to 8 0 N m 70 in Ib into a new hole or 5 5 N m 48 in Ib into a used hole do not over tighten Reconnect the breather hose and perform the governor adjustment See Section 5 Initial Governor Adjustment Install the air cleaner element with the pleated side out and seat the rubber seal onto the edges of the air cleaner base Install the serviced precleaner if So equipped into the air cleaner cover Make sure the hole in the precleaner is aligned with the upper mounting knob Reinstall the air cleaner cover and secure with the two knobs 4 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 4 Air Cleaner and Air Intake System Air Intake Cooling System Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times Annually or every 100 hours of operation more often under extremely dusty dirty conditions remove the blower housing
118. ockwise to lower the RPM Governed Idle Adjustment An optional governed idle control system is supplied on some engines The purpose of this system is to maintain a desired idle soeed regardless of ambient conditions temperature parasitic load etc that may change The system requires an additional procedure for setting the idle speed If soeed adjustments are required proceed as follows 1 Make any necessary speed or control adjustments following the appropriate instructions already covered in this section 2 Move the throttle control to the idle position Hold the governor lever away from the carburetor so the throttle lever is tight against the idle speed adjusting screw Check the speed with a tachometer and adjust it to 1500 1750 RPM Section 5 Fuel System and Governor 3 Release the governor lever and allow the engine to return to the governed idle speed Check it with a tachometer against the equipment manufacturers recommended idle speed If adjustment is necessary use the governed idle adjusting screw on the speed control assembly see Figure 5 19 Turn the screw clockwise to increase the governed idle speed and counterclockwise to decrease it WW 0 iy b J h r WX g Daer BASE Governed Idle rae oe See Se pie RE KZ SE Ee GE ting Y EN Ze mee Figure 5 19 Location of Governed Idle Adju Screw mi Governor These engines are equipped with a centrifugal flyweight m
119. om Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Battery A 12 volt battery with a minimum current rating of 250 cold cranking amps is recommended The actual cold cranking amp requirement depends on engine size application and starting temperatures As temperatures decrease cranking requirements increase but battery capacity shrinks Refer to the operating instructions of the equipment this engine powers for specific battery requirements If the battery charge is not sufficient to crank the engine recharge the battery Do not jump start using another battery Battery Charging A WARNING Explosive Gases Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Battery Maintenance Regular maintenance will ensure the battery will accept and hold a charge 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfi
120. om for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel System The typical fuel system and related components include the fuel tank in line fuel filter fuel pump carburetor and fuel lines Some applications use gravity feed without a fuel pump Operation The fuel from the tank is moved through the in line filter and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet and gravity moves the fuel Fuel then enters the carburetor float bowl and is moved into the carburetor body There the fuel is mixed with air This fuel air
121. on 7 See Figure 9 1 At cranking speeds 700 RPM or e hn Pde Cam Lobe lower the spring holds the flyweight in and the Pri e rounded surface of the control pin protrudes above the exhaust cam lobe This pushes the exhaust valve off its seat during the first part of the compression stroke The compression is reduced to an effective ratio of about 2 1 during cranking Flyweight After starting when engine speed exceeds 700 RPM centrifugal force overcomes the force of the flyweight spring The flyweight moves outward rotating the control pin to expose the flat surface which is lower than the cam lobe The control pin no longer has any effect on the exhaust valve and the engine operates at Figure 9 1 ACR Details full power 9 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning Benefits Reducing the compression at cranking speeds results in several important benefits 1 The starter and battery can be smaller more practical for the applications in which these engines are used 2 ACR eliminates kickback during starting so a spark retard advance mechanism is no longer required 3 The choke control setting is less critical with ACR In the event of flooding excess fuel is blown out the opened exhaust valve and does not hamper starting 4 Engines with ACR start much faster in cold weather 5 Engines with ACR can be
122. onstant When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing engine speed This action takes place very rapidly so a reduction in speed is hardly noticed As the speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again be in equilibrium This maintains the engine speed at a relatively constant level The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the application Initial Adjustment Make this initial adjustment whenever the governor arm is loosened or removed from the cross shaft To ensure proper setting make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor See Figures 5 21 and 5 22 5 14 1 Move the governor lever toward the carburetor wide open throttle Do not apply excess force flexing or distorting the throttle link 2 Grasp the cross shaft with pliers and turn the shaft counterclockwise as far as it will go then tighten the hex nut Torque the hex nut to 7 0 8 5 N m 60 75 in Ib Figure 5 21 Figure 5 22 Tightening Governor Lever Nut www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Gover
123. ool when measuring www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning 3 When the bore is within 0 064 mm 0 0025 in of Measuring Piston to Bore Clearance desired size remove the coarse stones and Before installing the piston into the cylinder bore it is replace with burnishing stones Continue with the necessary that the clearance be accurately checked burnishing stones until within 0 013 mm This step is often overlooked and if the clearances 0 0005 in of desired size and then use finish are not within specifications engine failure will usually stones 220 280 grit and polish to final size A result crosshatch should be observed if honing is done correctly The crosshatch should intersect at NOTE Do not use a feeler gauge to measure piston approximately 23 33 off the horizontal Too flat to bore clearance it will yield inaccurate an angle could cause the rings to skip and wear measurements Always use a micrometer excessively too steep an angle will result in high oil consumption refer to Figure 9 2 Use the following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston perpendicular to the piston pin up 8 mm 0 314 in from the bottom of the piston skirt as indicated in Figure 9 3 Measure 8 mm 0 314 in Above the Bottom of Piston Skirt at Right Angles to Piston
124. or 4 0 N m 35 in Ib into used holes See Figure 10 67 ST z d e e E ST a Figure 10 67 Installing Fuel Pump Mounting Bracket 2 Attach the fuel pump to the bracket so the pulse fitting is oriented in the four o clock position Secure with the two M6 screws Torque the screws to 5 9 N m 52 in Ib Do not over tighten www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly 3 Connect the pulse and fuel lines to the fuel pump and secure with clamps See Figure 10 68 Figure 10 70 Installing Blower Housing 2 Check that the stator leads are within the notch of Figure 10 68 Installing Fuel Pump the blower housing Align the mounting locations then install the four M6 shouldered mounting Install Rectifier Regulator screws If a flat washer was used under the head 1 Using the two M6 screws mount the rectifier on one screw install the screw in the location regulator onto the crankcase bosses with the closest to oil fill dipstick Torque the screws to cooling fins out See Figure 10 69 Torque the 11 0 N m 95 in Ib into new as cast holes or screws to 6 0 N m 55 in Ib into new as cast 7 5 N m 65 in Ib into used holes See Figure holes or 4 0 N m 35 in Ib into used holes 10 71 2 Attach the connector to the rectifier regulator terminals Figure 10 71 Installing Blower Housing Screws gt B 3 Snap the grass screen onto the coo
125. or the connecting rod is away from the cylinder See Figure 10 14 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Figure 10 14 Installing Crankshaft Assembly Figure 10 16 Assembled Piston and Connecting Rod 4 Install the balance weight guide shoe onto the guide pin with the solid end toward the Install Piston and Connecting Rod crankshaft See Figure 10 15 NOTE Proper orientation of the piston connecting rod inside the engine is extremely important Improper orientation can cause extensive wear or damage 1 Stagger the piston rings in the grooves until the end gaps are 120 apart Lubricate the cylinder bore crankshaft journal connecting rod journal piston and rings with engine oil 2 Compress the piston rings using a piston ring compressor Orient the FLY mark on the piston toward the flywheel side of the crankcase See Figure 10 17 Place the ring compressor on the top surface of the crankcase and make certain it is seated down around the entire circumference Use a soft rubber grip hammer handle and tap the piston connecting rod into the bore See Figure 10 18 The first tap should be rather firm so the oil ring moves from the compressor into Install Piston Rings NOTE For detailed piston inspection procedures and piston ring installation refer to Section 9 the bore in one smooth quick motion Otherwise 10 Inspection and Recondit
126. ow Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations The recommended low idle speed for basic engines is 1500 RPM To ensure best results when setting the low idle fuel needle the low idle soeed must not exceed 1500 RPM 75 RPM 5 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Disassembly Dust Seal Throttle Plate Screw s K Throttle Plate wy Low Idle Speed Adjusting eg Screw and Spring op Ke Fuel Inlet Low Idle Fuel Adjusting Needle _f Needle and Spring with Limiter Cap Fuel Shut off Solenoid e Figure 5 5 Carburetor Exploded View 1 Remove the bowl retaining screw or fuel shut off solenoid retaining screw gasket and fuel bowl 2 Remove the bowl gasket float shaft float and fuel inlet needle 3 Do not attempt to remove the low idle fuel adjustment needle if it has a limiter cap Further disassembly to remove the welch plugs main fuel jet throttle plate and shaft and choke plate and shaft is recommended only if these parts are to be cleaned or replaced 5 6 Throttle Lever and Shaft Choke Lever and Shaft choke Return Sp
127. psi the switch contacts open At oil pressures below approximately 2 to 5 psi the switch contacts close 6 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 6 Lubrication System On vehicular applications lawn tractors mowers etc the pressure switch can be used to activate a low oil warning light On stationary or unattended applications the pressure switch can be used to ground the ignition module to stop the engine NOTE Oil Sentry is not a substitute for checking the oil level BEFORE EACH USE Make sure the oil level is maintained up to the F mark on the dipstick Installation The pressure switch is installed into the center oil galley of the filter adapter casting on the closure plate Based on the application an elbow adapter may also be used See Figure 6 9 On engines not equipped with Oil Sentry the oil galley is sealed with a 1 8 pipe plug E Vid p a 4 A Pressure Switch To install the Oil Sentry switch 1 Remove and discard the pipe plug from the center passage of oil filter mounting pad 2 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the 90 adapter if used and the Oil Sentry switch 3 Install the adapter if used and carefully tighten it to the intended position Do not over tighten or damage the adapter 4 Install the switch into the adapter or center passage
128. r if so equipped into the upper section of the air cleaner cover See Figure 10 76 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Reassembly Figure 10 76 Installing Precleaner 3 Install the air cleaner cover and secure with the two retaining knobs See Figure 10 77 Figure 10 77 Installing Air Cleaner Cover Install Muffler 1 Install the gasket muffler and hex flange nuts on the exhaust port studs Leave the nuts slightly loose 2 lf an auxiliary muffler bracket is used install the M6 hex flange screw s into the bracket 3 Torque the hex flange nuts to 24 4 N m 216 in Ib See Figure 10 78 Torque the screws to 7 5 N m 65 in Ib Figure 10 78 Torquing Exhaust Flange Nuts Install Drain Plug Oil Filter and Oil 1 Install the oil drain plug and torque to 14 N m 125 in Ib Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material Put a drop of oil on your fingertip and wipe it onto the rubber gasket Thread the filter onto the engine until the rubber gasket contacts the surface then tighten the filter an additional 2 3 1 turn See Figure 10 79 Fill the crankcase with new oil of the proper type to the F mark on th
129. r tubes Leave the other tube open to the atmosphere Check that the water level in the manometer is at the 0 line Make sure the pinch clamp is closed 4 Section 3 Troubleshooting Start the engine and run at no load high idle speed 3200 to 3750 RPM Open the clamp and note the water level in the tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is the same as the open side no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below Close the pinch clamp before stopping the engine To perform the test with the vacuum pressure gauge 1 2 Insert the stopper as in step 1 Insert the barbed gauge fitting into the hole in the stopper Be sure the gauge needle is at 0 Run the engine as in step 2 and observe the gauge reading Needle movement to the left of 0 is a vacuum and movement to the right indicates a pressure A minimum of 10 2 cm 4 in of vacuum should be present Incorrect Vacuum in Crankcase Possible Cause Po Solution S 1 1 Crankcase breather clogged or inoperative Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blowby or leaky valves Confirm with cylinder leakdown test Restricted exhaust Disassemble breather clean parts thoroughly reassemble and rech
130. rankshaft Eccentric 9 4 3 The running clearance is the eccentric diameter subtracted from the balance weight bearing diameter step 1 minus step 2 If the measurements are outside the maximum wear limits listed in Section 1 the affected component s must be replaced Measuring Balance Weight Guide Pin and Guide Shoe to Closure Plate Guide Channel Running Clearance 1 Use an outside micrometer and measure the outside width of the balance weight guide shoe See Figure 9 6 Figure 9 6 Measuring Balance Weight Guide Shoe 2 Use an inside micrometer telescoping gauge or similar tool and measure the width of the guide channel in the closure plate See Figure 9 7 Record these dimensions Figure 9 7 Measuring Guide Channel in Closure Plate www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning 3 Use an outside micrometer again and measure If any of the measurements taken are outside the the O D of the balance weight guide pin See maximum wear limits listed in Section 1 the affected Figure 9 8 component s must be replaced Flywheel Inspection Inspect the flywheel for cracks and check the keyway for wear or damage Replace the flywheel if cracked If the flywheel key is sheared or the keyway is damaged replace the crankshaft flywheel and key Inspect the ring gear for cracks or damage Ring gears are not available separately Repla
131. recharge or replace Battery battery as necessary 2 Battery too small must be at least 250 cold cranking amps Check for excessively dirty or worn brushes and commutator Starter Clean commutator using a coarse cloth not emery cloth Energizes Replace brushes if excessively or unevenly worn rn en oe e Make sure the clutch or transmission is disengaged or placed in Slowly ae agg neutral This is especially important on equipment with hydrostatic drive The transmission must be exactly in neutral to prevent resistance which could keep the engine from starting Check for seized engine components such as the bearings connecting rod and piston Transmission or Engine 7 14 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Starter Removal and Installation Refer to the Disassembly and Reassembly Sections for starter removal and installation procedures Starter Drive Service Every three years or 150 hours of operation clean and lubricate the splines on the starter drive shaft If the drive pinion is worn or has chipped or broken teeth it must be replaced See Figure 7 12 It is not necessary to completely disassemble the starter to service the drive components Spring Retainer __ Retaining Ring Anti Drift Spring Drive Pinion Drive Nut Collar O Figure 7 12 Drive Components 1
132. resulting in the end of the drive shaft it rotates the flywheel and damage to the starter cranks the engine NOTE Ifthe starter does not crank the engine shut When the engine starts the flywheel rotates faster off the starter immediately Do not make than the starter armature and drive pinion This moves further attempts to start the engine until the the drive pinion out of mesh with the ring gear and into condition is corrected the retracted position When power is removed from the starter the armature stops rotating and the drive NOTE Do not drop the starter or strike the starter pinion is held in the retracted position by the anti drift frame or end cap Doing so can damage the spring Starter Starting Motor Precautions NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor Troubleshooting Guide Starting Difficulties Possible Fault 1 Check the specific gravity of battery If low recharge or replace Battery battery as necessary Starter Wiring Geh corroded Ee tighten loose connections Does Not Replace wires Im poor conaition Energize Starter Switch 1 Bypass the switch or solenoid with a jumper wire If starter cranks or Solenoid normally replace the faulty components Check the specific gravity of battery If low
133. ring Choke Plate j Float Ns Float Shaft C Bowl Gasket Fuel Bowl 2 gt TN eS Bowl Retaining Screw Gasket or Bowl Retaining Screw Welch Plug Removal In order to clean the idle ports and bowl vent thoroughly remove the welch plugs covering these areas Use SPX Tool No KO1018 and the following procedure to remove the welch plugs See Figure 5 6 1 Pierce the welch plug with the tip of the tool NOTE To prevent damage to the carburetor do not allow the tool to strike the carburetor body 2 Pry out the welch plug with the tip of the tool www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Do Not Allow Tip to Strike Carburetor Body Pierce Plug with Tip Welch Plug Figure 5 6 Removing Welch Plug Main Fuel Jet Removal The main jet is pressed into the side of the tower portion of the body Removal is not recommended unless a high altitude kit is being installed in which case the removal instructions will be included in the kit Fuel Inlet Seat Removal The fuel inlet seat is pressed into the carburetor body do not attempt to remove it If necessary clean it in place with aerosol carburetor cleaner Choke Shaft Removal 1 Because the edges of the choke plate are beveled mark the choke plate and carburetor body to ensure correct reassembly See Figure 5 7 Also note the choke plate position in the bore and the position of the choke lever
134. ructions for servicing the drive from the positive brush lead stud Remove the thru bolts and recessed hex nuts Remove the commutator end cap and lift out the brush carrier assembly with the brushes and springs Remove the drive end cap then pull the armature with the thrust washer and wave washer as equipped out of the starter frame 3 Retaining Ring 2 Retainer 5 Anti Drift Spring Pinion O Drive Nut Collar Flange Nuts EV Drive End Cap O must Washer Wave Washer Insulating Washer Hex Flange Nut Thru Bolts Figure 7 16 Inertia Drive Electric Starter www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Brush Replacement 1 Remove the hex flange nut and insulating washer from the positive brush lead stud 2 Remove the thru bolts and captured hex nuts 3 Remove the commutator end cap then pull the brush carrier assembly out of the frame See Figure 7 17 Figure 7 17 Removing Brush Carrier Assembly Commutator Service Clean the commutator with a coarse lint free cloth Do not use emery cloth If the commutator is badly worn or grooved turn it down on a lathe or replace the armature Starter Reassembly 1 Place the wave washer followed by the thrust washer onto the drive shaft of the armature See Figure 7 18 d E KR AN H A Wl R vg Figure 7 18 Washers Installed on Armature Section 7 Electri
135. specting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly operating breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with a water manometer or vacuum pressure test gauge See Section 2 Complete instructions are provided with the testers Test the crankcase vacuum with the manometer as follows 1 Insert the rubber stopper into the oil fill hole Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect the hose between the stopper and one of the manomete
136. st the stop screw which means it is properly set Choke Control Installation 1 Connect the choke cable boden wire to the engine choke control lever on the speed control bracket assembly 2 Position the choke cable under the cable clamp 3 Push move the choke control to the off position in the application panel until it bottoms then pull it back approximately 1 16 5 12 4 Push on the choke cable ahead of the clamp on the engine control plate until the choke lever stops Do not force Then tighten the cable clamp screw 5 Move the choke control until it stops on position Check that the choke link cannot be moved towards the carburetor by applying finger pressure on the lower link lever below the engine control plate If the choke link moves readjust by following steps 3 and 4 6 Push move the choke control in down until it bottoms The choke lever and link should be to the right at the end of its travel with linkage free so the engine does not run on partial choke d r B W PFA s aa i M ki Ge amp e Fw f ES KL di Figure 5 18 Separate Choke and Throttle Cable Controls Starting an Engine Equipped with Separate Control Cables 1 Place the throttle control midway between the slow and fast positions Place the choke control into the on position 2 Start the engine 3 Fora Cold Engine Gradually return the choke control to
137. sure Plate 1 Remove the governor gear and regulating pin assembly Gently pry upward using the blades of two small screwdrivers See Figure 8 37 NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed these tabs are destroyed and the gear must be replaced Governor gear removal is required for closure plate disassembly and cleaning of the oil passages a y TN Ex s Figure 8 37 Removing Governor Gear 2 Remove the six screws securing the oil passage cover to the closure plate Remove the cover and gasket See Figure 8 38 Figure 8 38 Removing Oil Passage Cover and Gasket Remove Cam Gears Cam Shafts and Oil Pump 1 Remove the thrust washers and cam gears from the cam shafts See Figure 8 39 8 10 NOTE The ACR weight and spring normally captured by the thrust washer and installation of closure plate will fall out if the exhaust cam gear is turned upside down Figure 8 39 Removing Cam Gears 2 Remove the screws securing the cam levers to the crankcase See Figure 8 40 Mark the cam levers for proper reassembly Figure 8 40 Removing Cam Levers 3 Pullthe exhaust side cam shaft and slotted thrust washer out of the crankcase See Figure 8 41 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 L Ai Figure 8 41 Removing Exhaust Side Cam Shaft and Slotted Thrust Washer 4 Remove the two screws securi
138. t remove the engine spark plug Check wires and terminals of ignition aa module and other components for b Make sure the engine ignition switch accidental grounding and damaged kill switch or key switch is in the run insulation ition i i DOS If wires and terminals are OK the ignition module is probably faulty and should be replaced Test module further using an ohmmeter Test 4 Crank the engine minimum speed 500 RPM and observe the tester Visible and audible sparks should be produced Measure the resistance of module 4 Ifthe resistance is low or 0 ohms the secondary using an ohmmeter See Figures module secondary is shorted Replace the 7 2 and 7 5 module Zero ohmmeter before testing Connect If the resistance is high or infinity ohms one ohmmeter lead to laminations A the module secondary is open Replace the Connect the other lead to the spark plug module terminal C of high terminal lead With the If the resistance is within the specified ohmmeter leads connected in this manner range the module secondary is OK the resistance of secondary should be 7 900 to 18 400 ohms NOTE This test cannot be performed Refer to the Disassembly and Reassembly unless module has been fired at Sections for complete ignition module least once removal and installation procedures Figure 7 4 Ignition Tester SPX Part No KO1046 Figure 7 5 Testing CD Ignition Module Secondary 7 5 www mymowerparts c
139. t the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up Maintenance Required Fill fuel tank Daily or Before Check oil level Starting Engine Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Every 2 Months Service precleaner element if equipped or 25 Hours Service air cleaner element if not equipped with precleaner Replace air cleaner element if equipped with precleaner Change oil and filter refer to Viscosity Table Page 1 4 based on seasonal temperatures Remove blower housing and clean cooling areas Check that all fasteners are in place and components are properly secured Replace fuel filter Every 2 Years or e Check spark plug condition and gap 200 Hours e Have bendix starter drive serviced E 200 H EES e Have valve lash checked adjusted Every 500 Hours e Replace spark plug Perform these maintenance procedures more frequently under extremely dusty dirty conditions 2Have a Kohler Engine Service Dealer perform this service Annually or Every 100 Hours Storage If the engine will be out of service for two months or To empty the system run the engine until the tank more use the following storage procedure and system are empty
140. tal contact with the wall causing scuffing and scoring Scoring of the cylinder wall can also be caused by localized hot spots from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is scored worn tapered or out of round resizing may be possible Use an inside micrometer or telescoping gauge to determine the amount of wear refer to Section 1 If wear exceeds the published limits a 0 08 mm 0 003 in oversize piston is available If the cylinder will not clean up at 0 08 mm 0 003 in oversize a short block or replacement engine will need to be considered Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft counter bore Honing is best accomplished at a drill soeed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower the hone into the bore and after centering adjust it so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start the drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently Make sure the bore is c
141. te colored deposits indicate overheating This condition is usually accompanied by excessive gap erosion A clogged grass screen clogged cooling fins and lean carburetion are some causes of overheating Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be regapped and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion Incomplete combustion is usually caused by over rich carburetion weak ignition or poor compression Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more than the correct gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by operating the engine with too much choke or a dirty air filter Oil in the combustion chamber is usually caused by worn piston rings or valve guides 7 2 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Electrical System and Components Electronic CD Ignition System Spark Plug SCH Spark Plug Terminal C Spark Plug Air Gap d 0 203 0 305 mm Zee 0 008 0 012 in Kg Ignition Module Kill Switch or Off Position of Key Switch Figure 7 2 Electronic CD Ignition System These engines are equipped with a depen
142. the off position after the engine starts and warms up The engine equipment may be operated during the warm up period but it may be necessary to leave the choke partially on until the engine warms up 4 Fora Warm Engine Return choke to off position as soon as engine starts www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Changing the High Speed RPM on the Engines with Separate Controls Increase or Decrease RPM 1 Check that the governor spring and installation matches the intended high soeed RPM operating range Refer to Figure 5 23 2 Start the engine move the application throttle lever to full throttle fast and loosen the mounting screws of the main speed control bracket to allow repositioning See Figure 5 17 3 To increase the RPM Move the speed control bracket towards the carburetor To decrease the RPM Move the speed control bracket away from the carburetor Check the RPM with a tachometer and tighten screws when correct setting has been obtained 4 To ensure that the RPM has been obtained move the throttle lever to low idle slow then back to full throttle fast position and check the RPM witha tachometer Setting the Low Idle RPM 1 Move the application control to slow position 2 Using a tachometer check the RPM Then using a screwdriver turn the low idle speed screw see Figure 5 3 inward clockwise to increase the RPM and outward countercl
143. the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation 9 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Inspection and Reconditioning When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes ona shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts that meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked fins improperly seated valve or wrong spark plug See Figure 9 12 for some common types of piston and ring damage Overheated or Deteriorated Oil Replacement pistons are ava
144. tion 9 Inspection and Reconditioning Make sure governor gear assembly rotates freely 6 Complete engine reassembly following Reassembly procedures Check that timing marks are still aligned 7 When engine reassembly is completed reset Install a new closure plate gasket and install the initial governor adjustment according to closure plate Refer to Reassembly Section 10 procedure in Fuel System and Governor for proper torque sequence and specification Section 5 9 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 SV470 600 Section 10 Reassembly The following sequence is suggested for complete 23 Install and adjust governor lever mounting speed engine reassembly This procedure assumes that all control bracket components are new or have been reconditioned and 24 Install fuel pump Some models all component subassembly work has been 25 Install rectifier regulator completed This procedure may be varied to 26 Install blower housing and flywheel screen accommodate options or special equipment 27 Install Oil Sentry switch or pipe plug 28 Install air cleaner element precleaner and air NOTE Make sure the engine is assembled using all cleaner cover specified torque values tightening 29 Install muffler sequences and clearances Failure to observe specifications could cause severe Install PTO Side Oil Seal engine wear or damage 1 Apply a small amou
145. tion away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present A Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine The engine identification numbers appear on a decal affixed to t
146. ttom of the threads Allow a minute or two for the oil to be absorbed by the filter material 6 Putadrop of oil on your fingertip and wipe it on the rubber gasket www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 6 Lubrication System 7 Install the replacement oil filter to the mounting pad Turn the oil filter clockwise until the rubber gasket contacts the pad and then tighten the filter an additional 2 3 to 1 turn 8 Fill the crankcase with new oil of the proper type to the F mark on the dipstick 9 Reinstall the oil fill cap dipstick and push firmly into place 10 Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Add more oil as necessary so the oil level is up to but not over the F mark NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Full Pressure Lubrication System Operation This engine uses a full pressure lubrication system to deliver oil for internal lubrication Acam driven high efficiency Gerotor oil pump located in the crankcase maintains proper oil flow and oil pressure even at low speeds and high operating temperatures Oil is supplied from the pump via two circuits to the crankshaft main be
147. y grease to the ends of the push rods Insert the push rods into the push rod bores and seat the lower end into the dimpled recess of the cam levers It may be necessary to lift or shift the lower end of the push rod slightly and feel that the rod seats into the recess Once seated hold it in place as you position the rocker arm The push rod must stay in the recess while the rocker arms are positioned and adjusted See Figure 10 38 Figure 10 38 Installing Push Rods and Rocker Arm Assemblies Section 10 Reassembly With the engine at TDC of the compression stroke insert a 0 076 mm 0 003 in flat feeler gauge between one of the valve stems and the rocker arm Tighten the adjustment nut with a wrench until a slight drag is felt on the feeler gauge Hold the nut in that position and torque the set screw 115 Torx drive to 5 5 N m 50 in Ib Perform the adjustment procedure on the other valve Proper valve clearance is 0 076 0 127 mm 0 003 0 005 in See Figures 10 39 and 10 40 Figure 10 40 Locking Adjustment Nut Set Screw Install Valve Cover 1 Make sure the sealing surfaces of the valve cover and cylinder head are clean and free of any nicks or burrs Install a new valve cover gasket followed by the valve cover Position any brackets that mount on the valve cover and start the seven mounting SCrews 10 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4

TP-2548 Courage Service Manual - K&T Parts House Lawn Mower

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TP-2548 Courage Service Manual - K&amp;T Parts House Lawn Mower

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TP-2548 Courage Service Manual - K&T Parts House Lawn Mower